Signature Series Vehicles C6 A6 Installation Guidelines

STāSIS Engineering

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Table of Contents

Page Torque specs 3 Suspension

Front and Rear Suspension, Touring 4

Braking Optional Brake Kit 16 Bed-In Procedure 21

Exhaust Exhaust Kit 22

Post Installation Checklist 25

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A6 TORQUE VALUES

Suspension and Wheels Front damper to upper mount 37 ft-lbs Front damper upper mount to body 56 ft-lbs Front damper fork to lower link 66 ft-lbs Upper link pinch bolt 29 ft-lbs Rear damper to upper mount 26 ft-lbs Rear damper upper mount to body 37 ft-lbs Rear damper to upright 111 ft-lbs Rear sway bar link to sway bar 30 ft-lbs Wheel lug bolts 90 ft-lbs

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A6 Suspension, Touring

Touring Suspension Kit

Parts List Qty Description 1 Stasis Performance Spring Kit 1 C6 A6 Rear Anti Roll bar Kit

Special Tools Required Qty Description Part Number 1 Torque Wrench VAG 1331 1 Torque Wrench VAG 1332 1 Engine/transmission jack VAG 1383 A 1 Spring Compressor VAG 1752/1 1 Spring Holder VAG 1752/7 1 Rear Spring Compressor VAS 6274 1 Supplementary Set VAS 6274/10

Please read ALL instructions prior to attempting installation. Please torque all fasteners to specifications.

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Front Removal and Installation

1 Before removing any parts, park the car on a secure, stable, and level surface. Remove wheel trim; pull trim cap off light-alloy wheels (using puller in vehicle tool kit) and loosen (but do not remove) the wheel lug nuts. Jack the vehicle up, and place the car on four stable jack stands or use a professional vehicle lift. We recommend having two people available for certain steps of the installation.

2 Remove wheels

3 Disconnect link on ride height sensor to prevent damage. NOTE: Driver’s side only

4 Remove top nut and bolt for anti-roll bar mount

6 Remove clevis bolt for lower shock mount

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7 A) Remove top bolt for steering arm B) Remove pinch bolt nut NOTE: Do not allow bolt to back out or turn. Remove nut, then remove bolt. Pull down gently on steering arm thus removing from upright

8 Remove the Upper Front Control Arm nut and bolt. Carefully pull up on control arms, thus removing from upright

NOTE: The slits in the upright must not be widened using a chisel or similar tool! This can cause the pinch arms to crack. If the control arm pins are stuck in the housing, tap lightly with a rubber mallet on the bottom of the control arms.

9 Peel back on rubber seal and remove

Now remove plastic cover to reveal control arm girdle bolts

10 Remove bolts caps.

NOTE: These are easily removed with long nose pliers

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11 NOTE: 2 persons preferred

Person 1: Hold up damper assembly from underneath car

Person 2: Remove 3 mounting bolts. Alternate evenly between all 3

12 Carefully remove entire assembly.

13 Use an adequate spring compressor to compress spring on shock assembly.

NOTE: Orientation of rubber mounts and corresponding washers upon removal of control arm girdle

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14 Image after removal of control arm girdle.

Remove OEM spring and bumpstop

15 Accurately cut top of bump stop so final length below dashed line is: 3 1/8 ”

16 Install front lowering spring and modified bumpstop

17 NOTE: Rotate lower rubber spring mount so spring registers properly on both upper and lower rubber mounts

18 Re-install control arm girdle. NOTE: DO NOT grab damper shaft with any tools while tightening the nylock nut. Reinstall using same tool as was used during removal

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Installation

1 Installation is the opposite of removal. When installing control arms and steering arm , please note: A) Slide steering arm into place, and tighten the pinch bolt B) If pinch bolt doesn’t go through, move arm vertically while gently pushing on bolt. C) Apply blue LOCTITE on threads for steering arm bolt, then tighten.

Rear Removal and Installation Perform installation of rear ARB at the same time *When performing complete Sig.Series package, removing OEM exhaust prior to ARB highly recommended* Torque Values

ARB Mounting Bracket Bolts, 10mm Triple Square 29 N m Lower Drop Link Bolts 54 N m Upper Drop Link Bolts 54 N m Chassis Cross Brace Bolts 54 N m Exhaust Muffler Hanger Nuts 20 N m

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1 Before removing any parts, jack the vehicle up, and place the vehicle on four stable

jack stands or use a professional vehicle lift.

2 Support the exhaust and remove the two exhaust muffler hanger nuts (one per side), 13mm socket.

3 Gently pry the two center exhaust

rubber hangers of off the exhaust. Use a lubricant (i.e. WD-40) if required.

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4 Remove the center chassis cross brace, 16mm socket.

5 Lower exhaust to give clearance for

removal and installation of the ARB.

6 Loosen but do not remove the lower

ARB drop link bolts, 16mm socket.

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7 Disconnect upper ARB drop link bolts from the ARB and rotate link to the side, 16mm end wrenches

8 Remove the bolts attaching the ARB

brackets to the subframe (both sides), 10mm Triple Square Socket.

9 Remove the stock ARB from the car.

Gently pry off the ARB mount brackets and rubber bushings (these will be re-used with the STaSIS ARB). OEM ARB bushings have enough flex to accommodate the STaSIS ARB.

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11 Install STaSIS ARB into vehicle. It may be necessary to deflect the upper control arm by gently using a pry bar as shown to facilitate the installation.

12 Once located, installation is the

reverse of all removal steps. Make sure to locate drop link bolts into the ARB before tightening the ARB Mounting Bracket bolts. Torque all fasteners to the specifications shown. *NOTE*: After mounting to the vehicle, make sure your ARB is centered between the two clamps to avoid possible binding and interference with suspension components during vehicle operation.

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Remove wheels

1 Remove ride height sensor lever arm NOTE: Driver’s side only

2 Unscrew two torx fasteners to partially

remove inner fender liner

3 Remove lower damper mount bolt

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4 Remove nut and bolt for upper anti-roll bar mount

5 Pull away inner fender liner to reveal

upper damper mount bolts.

Loosen bolts, and remove damper

6 Remove bumpstop for modification.

Accurately cut top of bumpstop so final length below dashed line is: 4 3/4”

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7 Remove rear coil springs with spring compressor tool VAS 6274 and VAS 6274/10.

8 Install STaSIS rear spring with the

spring compressor. NOTE: Orient the progressive coils towards the top

9 Install damper assembly and torque to:

Upper bolt: 37 ft-lbs Lower bolt: 111 ft-lb Note – Bonded rubber suspension bushings can only be turned to a limited extent. The mounting bolts of the suspension links must only be tightened when the suspension is compressed to the curb weight position.

10 Install wheels and tighten. Lower the car onto its wheels and torque all wheel lug bolts to the recommended torque. Note: Check wheel alignment after suspension installation

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C6 A6 Performance Brakes

Performance Brake Kit

Parts List: Qty Description 1 Rotor Alcon 370X32 RH 1 Rotor Alcon 370X32 LH 4 SHCS M12x1.750x60 12.9 Blue 1 Caliper Alcon Mono6 RH Trailing 1 Caliper Alcon Mono6 LH Trailing 2 Bracket C6 A6 Mono6 1 Line Kit Audi Front Alcon 2 Brake Line Stop Washer 1 Pad Mono6 SBS Pro-Track 1 Fluid Motul 5.1

Installation Guidelines

• Torque all fasteners to specification. Do not use an impact wrench. • The rotors are side-specific, rotational direction is labeled. Open portion of crescents face toward the

direction of rotation. • The rotors have been dynamically balanced by machining the outer edge. Flat spots along the outer

diameter are normal and will not affect the performance of the rotor. • Tighten hydraulic connections with a line wrench. • Bleed brakes properly to assure proper brake operation; the use of a power bleeder is

recommended. • Ensure all ABS sensor and Pad wear sensor plugs are reconnected.

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• Proper pad bedding is essential to proper brake operation. • Initially drive the car with low braking force to check brake operation; then follow all steps listed in the

bedding process outlined at the end of this instruction manual. • During bedding do not thermally shock the rotors with aggressive braking before the rotors have come

up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake pressures as instructed in the bedding procedure.

• After bedding brakes re-torque wheel nuts to proper torque specifications. • If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double

check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor becomes uniform.

• If the vehicle is driven in adverse weather conditions, STaSIS Engineering recommends annual cleaning and inspection of the rotor crescents. A common source of vibration can be attributed to dirt completely filling in the crescents on the inboard side of the rotors which in turn will not allow the pad to function properly.

• Brake rotor wall thickness wear limit is 1.0 mm per side of rotor. Rotor face runout limit +/- 0.010 in, when taking measurement make sure rotor is tightened down to the hub at all 5 bolt locations.

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Instructions 1 Sort the parts in the brake kit for the right

and left side. Brake bleeders face upward. Caliper mounting brackets are universal. Install brake pads in calipers. Install brake lines with banjo bolt and crush washers. Orient brake line facing straight up as shown.

2 Raise vehicle and remove the front wheels. 3 Using brake cleaner, clean the brake line

connection at the body flange. Remove all dirt and debris from this area and from the line connection threads so that no dirt will get into the new brake line when it is installed.

4 Remove the caliper. Remove the ABS sensor wire from the holding bracket on the brake caliper to facilitate removing the caliper. Disconnect the brake pad wear sensor wire from the driver’s side front brake inner pad. Remove caliper mounting bolts (the bolts holding the caliper mounting bracket to the upright). Save these bolts as they will be reused. Remove caliper and support it so that the brake line is not under tension.

5 Remove the brake rotor. Clean the hub, removing all rust from the rotor mounting surface, the rotor pilot and wheel pilot. Apply some anti-seize to the pilot surface to prevent rotors and wheels from sticking in the future. Do not get any anti-seize on the rotor mounting surface of the hub.

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6 Install caliper mounting brackets using the stock mounting bolts and torque to 92 ft-lb. The bracket will mount to the outside face of the upright with the machined pockets on the bracket going against the upright. The OEM bolts will fit through the upright from the backside and thread into the bracket.

7 Install the new rotors making sure they are

free of dirt and grease. Tighten the rotor retaining bolt to 48 in-lbs.

8 Place the caliper with the brake pads

installed onto the caliper mounting bracket and install the caliper mounting bolts M12 x 1.75 x 60 and torque to 70 ft-lb. If the caliper will not go over the rotor because the pads are too close together, push the pads back using a pad spreader. Note: When rotating, the rotor must always pass the small caliper piston first. Therefore in a trailing caliper application like we have here the small caliper piston will be at the bottom of the caliper. The purpose is to insure even pad wear.

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9

Replace the front brake lines. Use an 11-mm line wrench on the hard line nut and a 16-mm wrench on the flats on the flex line hose-end. Remove the stock flexible line from the hard line and completely remove the stock caliper and line from the vehicle. Install the copper washer onto the new line as shown. Install the new flexible line, with washer using the stock spring clip under the hard line nut and clean with brake clean once tightened. Install the rubber brake line grommet into the factory bracket on the back of the upright. Re-connect all ABS sensor wires and the brake pad wear sensor.

10 Make sure that the brake rotor spins freely and that the rotor is flush on the hub.

11 Bleed the brakes using fresh high-quality brake fluid. A power bleeder is highly recommended. Two bleeders are on each front caliper. Bleed the outers first until no air exits, then the inners until no air exits Wait 10-15 minutes. Power bleed again while turning the ignition on/engine off and stroke the brake pedal five times when each bleeder is open. This process will assure a proper bleed with the ABS equipped system. Tighten all bleeders securely.

12 Clean all brake line connections with brake cleaner and compressed air so that they are clean and dry. Start engine and pressurize brake system several times and check for leaks at all the brake line connections. Correct any leaks before driving the car.

13 Check the clearance between the wheels and the new brake calipers. Make sure that there is at least 1/8”(0.125”) between the wheel and the caliper.

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14 Verify that all bolts are tight and torque the wheel lug bolts.

15 Test drive the car using the brakes gently.

16 WARNING: Do not aggressively test the brakes until they are properly bedded.

17 Bed the pads and rotors. See the Bedding Procedure attached to these installation instructions. After brakes are fully bedded recheck wheel lug bolt torque.

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STaSIS Bedding Procedure

After installing new pads, rotors, or both, it is necessary to properly bed the pad to the rotor before using the brakes to their full capacity.

What is bedding? Bedding is the process of depositing a layer of pad material (often called the transfer layer or transfer film) onto the surface of the rotor. Brake rotors used on OEM style brake systems do not require this transfer layer as the braking system is relying on friction between the pad and the rotor material to slow the vehicle down. On STaSIS rotors, the bond between the pad and the transfer layer is much stronger and the frictional characteristics of the pad/transfer layer interface are far better than those of a pad/rotor interface. It is therefore crucial to bed pads properly to ensure the reliability, performance, and longevity of your STaSIS/ALCON brake system.

When should I bed pads and rotors? Bedding is recommended whenever you install new pads or rotors, or experience vibrations while braking. • For new pads and rotors, bedding allows the manufacturing resins in the pads to burn off

slowly to avoid uneven deposits or pad glazing. Bedding also allows the rotors to relieve any thermal stresses incurred during the manufacturing process.

• Vibrations felt through the brake pedal are most commonly a result of uneven pad deposition, which is remedied by re-bedding the existing components.

Bedding Process 1. Upon initial installation do not bed the rotors immediately. Drive the vehicle with normal to

light braking for 1-2 days to allow the pad and rotor surfaces to conform better before bedding in at higher temperatures.

2. Find a suitable road. You will need a relatively straight road with minimal traffic where you can safely (and legally!) reach speeds up to 65 MPH.

3. Once the car has been driven with light braking for a few miles to bring the rotors up to the proper operating temperature, bring the car up to approximately 65 MPH. Gently apply constant pressure (about 10%) to the brakes, bringing the car down to about 20 MPH.

4. Accelerate briskly back to 65 MPH. Apply the brakes again, however this time use more force (about 20%).

5. Repeat steps 2 and 3, each successive time applying more pressure. Your last two brake applications should engage or nearly engage the ABS system.

6. Do not immediately stop the vehicle with your foot on the brakes after step 5, the concentrated heat from the pad sitting on a non-rotating rotor will warp the rotor. Drive vehicle using absolutely minimal brake application to cool the rotors to ambient temperature (freeway driving).

7. Once the system has cooled, repeat the entire process. After completing two heat cycles on the rotors, check the rotors for an even, slightly hazy coating (often with a slight blue tint). Any spotting or blotches indicate uneven pad deposition. Repeat the process until the rotor surface is even.

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C6 A6 Performance Exhaust

Exhaust Kit Installation

Parts List Qty Description 1 A6 Sig Series Twin Tip Exhaust

Instructions Removal and Installation

1 Stock exhaust pictured here:

2 A) Remove chassis cross brace

B) Loosen clamps that connect stock exhaust to catalytic convertors C) Slide support bar out from rubber hanger NOTE: Spraying lubricant inside rubber hanger eases removal

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3 Slide support bar out from rubber hangers on both sides. NOTE: Spraying lubricant inside rubber hanger eases removal

4 With all fasteners and clamps

removed/loosened, remove entire exhaust system as a whole

5 Ready for the installation of new STaSIS Performance exhaust system STaSIS Performance exhaust shown:

6 Start with installing the mid pipe to catalytic

convertors, and support bars into corresponding hangers

7 Now install passenger’s side rear section to mid pipe, followed by driver’s side. Make sure to install support bars into corresponding hangers NOTE: Leave clamps loose enough to allow for adjustment

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8 Reinstall hardware for adjustable bracket and tighten flanges and bracket with mufflers aligned and spaced evenly. Confirm the side-side distances are equal (x). Loosen nut (arrow) on adjustable bracket and align muffler as necessary. Torque nut to 23 Nm (17 ftlb Once the correct alignment has been achieved, torque down all band clamps Test drive and check for rattles. Re-adjust as necessary to provide proper clearance

NOTE: Ensure at least 1 ½” clearance

between exhaust pipes and heat shielding

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Signature Series Post Installation Checklist

Suspension

o Ensure front and rear swaybars have been reconnected

o Ensure front and rear ride sensing actuator rods have been reconnected

o Ensure all suspension and anti-roll bar mounting bolts were tightened with the suspension compressed to the curb weight position.

o Check ride height and alignment after driving the car for a few miles, as the rubber bushings will cause the car to settle.

Brakes

o Ensure all ABS sensor and Pad wear sensor plugs are reconnected

o Ensure brake line grommet is properly seated on bracket. Cycle steering from full lock left to full lock right (with the suspension compressed to the curb weight position) and inspect for possible binding on the brake line.

o After bleeding brakes, cycle pressure to the pedal and double check all bleed screws and brake line connections for possible leakage.

o Drive the car at low speeds for a few miles to check brake operation before beginning brake bedding procedure.

o During bedding do not thermally shock the rotors with aggressive braking before the rotors have come up to temperature. Cracks on new rotors can form due to thermal shock. Gradually increase brake pressures as instructed in the bedding procedure.

o After bedding brakes re-torque wheel nuts to proper torque specifications.

o After installation and bleeding is completed double check brake fluid level.

o If vibration occurs during normal usage, check for abnormal pad wear deposits on the rotor. Double check all fasteners and repeat the bedding process 2-3 cycles until the pad deposits on the rotor becomes uniform.

Exhaust

o During and after install, wipe off all assembly and shipping particles from the exhaust. If dust is not wiped off, once the exhaust gets hot, the particles burn onto the stainless steel finish and become permanent.

o Ensure the exhaust tips on both sides protrude from the bumper evenly and are not touching any body panels.

o Apply anti seize to all assembly bolts to allow for ease of removal.

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STāSIS Engineering

“Race Bred Adrenaline”