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#TL100087
DPK0021APR 2.0T MQB AWD Race DP System
TL100087W W W . G O A P R . C O M
4 8 0 0 U S H W Y 2 8 0 W e s t O p e l i k a A l a b a m a 3 6 8 0 1
Notes:
These instructions were written for a North American specification Audi A3 quattro, but other models, like the Audi S3 and Volkswagen Golf R, are similar.
When disassembling the car, be sure to keep all fasteners so they can be reused. It is recommend that you get some kind of compartmented tray to organize the fastners, such as a fishing tackle box or several large ice cube trays. Fasteners that are not reused for reinstallation are noted in the instructions. All directions used in this manual (right, left, front, etc.) are based on if you were sitting in the drivers seat of the car.
These instructions assume that you have basic mechanical skills and several varieties of the tools of basic hand tools in order to install the kit. If you have any questions about the install, feel free to contact your APR representative.
1) Secure the vehicle on a lift or on jack stands, and wait until the engine is cool before proceeding.
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2) Remove the engine cover by carefully lifting up all four corners. Remove the 6mm allen screw on the top of the V-band clamp.
3) Use a screwdriver or prybar to open up the two tabs of the V-band clamp, and remove the clamp from the car.
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4) Remove the electrical connector to the secondary oxygen sensor from the mounting bracket located on the back of the engine firewall. Discon-nect the electrical connector and separate the harness from the four mounting clips on the firewall.
5) Using an oxygen sensor socket, remove the secondary oxygen sensor from the DP just past the catalyst.
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6) Remove the two 13mm nuts from back side of the factory DP support bracket, leaving the bracket attached to the engine.
7) Underneath the car, remove the two T25 screws and two push pin fasteners from the panel by the DP hanger mount, and remove the panel from the car.
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8) Remove the three T45 screws from the back of the belly pan. Remove the seven T25 screws from the belly pan. Finally, using a flat-head screwdriver, separate the front of the belly pan from the bottom of the front bumper and remove the belly pan from the car.
9) From underneath the car, remove the one 10mm triple square bolt holding the left side of the differential heat shield.
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10) Using a long, ball end, 8mm allen socket, remove the two nuts holding the right axle heat shield to the differential, and remove the heat shield from the car.
11) Remove the 16mm nut that holds the right side of the differential heat shield, and remove the differen-tial heat shield from the car.
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12) Remove the two 16mm bolts from the lower transmission mount.
13) Remove the three 12 point 10mm bolts holding the driveshaft to the front differential. It may be necessary to put the car in neutral to rotate the driveshaft in order to access the bolts.
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14) Loosen the two 13mm nuts on the rear of the stock DP where it con-nects to the stock catback exhaust.
15) Using a pry bar, rock the lower side of the engine and transmission towards the front of the car. With the lower side of the engine forward, pull the driveshaft off the differential and swing it towards the left side of the center tunnel. Carefully let the engine and transmission rock back to its resting location.
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16) Lower the rear portion of the stock DP, pulling the DP hangers out of the rubber bushings of the DP hanger mount.
17) Pulling the DP back further, rotate the DP counter-clockwise.
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18) Continue to rotate the DP coun-ter-clockwise while you pull it back. The DP should be rotated about 180º by the time it can be removed from the center tunnel.
19) Remove the stock DP mount-ing bracket from the car by removing the two 13mm nuts holding it to the engine block.
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20) Install the APR Race DP bracket in the rubber bushings of the DP hanger mount. Lubricate the APR bracket before installing to prevent from tearing the stock rubber bush-ings.
21) Place the APR Race DP in the car so that the top flange of the Race DP meets the outlet flange of the turbo. Temporarily loosely install the supplied bolt and nut to hold the DP to the APR Race DP bracket.
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22) From above, loosely install the factory V-band clamp to secure the Race DP to the turbocharger, and loosely install the factory bolt. Do not tighten this joint yet.
23) Remove the nut and bolt hold-ing the Race DP to the APR Race DP bracket. Using a pry bar, rock the lower side of the engine and trans-mission forward.
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24) Place the driveshaft back to its original mounting location. As you swing the lower side of the engine and transmission back, make sure the center post on the differential slides into the correct hole of the driveshaft. If the center post does not go in the hole in the driveshaft, the bushing can be damaged, result-ing in the replacement of the drive-shaft.
25) Pry the engine back and thread in the two lower 16mm transmis-sion mount bolts by hand. Torque to 70Nm (50ft-lb).
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26) Loosely reinstall the 15mm bolt and nut connecting the Race DP to the APR Race DP bracket. Loosely install the midpipe in the car with the two supplied sleeved clamps and the reducing coupler. NOTE: If fitting to an Audi TT/TT-S, trim some length off the back side of the midpipe to fit the shorter wheel-base of the TT.
27) Manipulate the midpipe of the exhaust in the center tunnel until everything fits well, and then begin tightening the 13mm bolts on the sleeve clamps from the rear of the car towards the front of the car.
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28) Tighten the 15mm bolt and nut holding the Race DP to the Race DP bracket.
29) Install the secondary oxygen sensor in the APR midpipe with an oxygen sensor socket and torque to 55Nm (40 lb-ft).
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30) Tighten the V-band clamp hold-ing the Race DP to the turbocharger, and torque to 15Nm (11 lb-ft). Rein-stall the engine cover on top of the engine by pressing the four corners down on the appropriate posts.
31) Attach the APR extension har-ness to the factory connector near the back of the engine firewall. Mount the harness in the factory bracket on the firewall. Route the harness down in front of the brake booster and to the right side of the shifter cable.
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32) Loosen the 10mm nut from the front of the left plastic underbody panel.
33) Route the APR extension har-ness over and behind the power steering wiring harness and follow the factory brake lines down to the bottom of the car.
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34) Route the factory harness from the secondary oxygen sensor towards the left side of the car, underneath the plastic underbody panel. Tuck the harness between the center tunnel heat shield and the body, and secure to the hole in the heat shield with a cable tie.
35) Continue to route the second-ary oxygen sensor harness forward, between the heat shield and body, and secure to the front hole in the heat shield with a cable tie. Con-nect the factory harness to the APR extension harness, and secure near the brake lines. Lift the left plastic underbody panel back to its original mounting location, and secure with the 10mm factory nut.
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36) Install the three new 12 point 10mm bolts holding the driveshaft to the differential. Torque the bolts to 50Nm (37 lb-ft), and then tighten the bolts an additional 90°.
37) Reinstall the factory differen-tial heat shield, and secure with the 10mm triple square bolt on the left and the 16mm bolt on the right.
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38) Reinstall the right axle heat shield with the two original 8mm allen bolts.
39) Install the belly pan on the car, making sure the two front tabs on the belly pan slide into the correct slot on the bottom of the front bumper. Install the three T45 screws to the back of the belly pan. Install the seven T25 screws securing the belly pan.
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#TL100087
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