Signature Series Vehicles C6 A6 Installation Guidelines

Transcription

1 STāSIS Engineering Signature Series Vehicles C6 A6 Installatin Guidelines

2 Table f Cntents Page Trque specs 3 Suspensin Frnt and Rear Suspensin, Turing 4 Braking Optinal Brake Kit 16 Bed-In Prcedure 21 Exhaust Exhaust Kit 22 Pst Installatin Checklist 25 2 f 28

3 A6 TORQUE VALUES Suspensin and Wheels Frnt damper t upper munt Frnt damper upper munt t bdy Frnt damper frk t lwer link Upper link pinch blt Rear damper t upper munt Rear damper upper munt t bdy Rear damper t upright Rear sway bar link t sway bar Wheel lug blts 37 ft-lbs 56 ft-lbs 66 ft-lbs 29 ft-lbs 26 ft-lbs 37 ft-lbs 111 ft-lbs 30 ft-lbs 90 ft-lbs 3 f 28

4 A6 Suspensin, Turing Turing Suspensin Kit Parts List Qty Descriptin 1 Stasis Perfrmance Spring Kit 1 C6 A6 Rear Anti Rll bar Kit Special Tls Required Qty Descriptin Part Number 1 Trque Wrench VAG Trque Wrench VAG Engine/transmissin jack VAG 1383 A 1 Spring Cmpressr VAG 1752/1 1 Spring Hlder VAG 1752/7 1 Rear Spring Cmpressr VAS Supplementary Set VAS 6274/10 Please read ALL instructins prir t attempting installatin. Please trque all fasteners t specificatins. 4 f 28

5 Frnt Remval and Installatin 1 Befre remving any parts, park the car n a secure, stable, and level surface. Remve wheel trim; pull trim cap ff light-ally wheels (using puller in vehicle tl kit) and lsen (but d nt remve) the wheel lug nuts. Jack the vehicle up, and place the car n fur stable jack stands r use a prfessinal vehicle lift. We recmmend having tw peple available fr certain steps f the installatin. 2 Remve wheels 3 Discnnect link n ride height sensr t prevent damage. NOTE: Driver s side nly 4 Remve tp nut and blt fr anti-rll bar munt 6 Remve clevis blt fr lwer shck munt 5 f 28

6 7 A) Remve tp blt fr steering arm B) Remve pinch blt nut NOTE: D nt allw blt t back ut r turn. Remve nut, then remve blt. Pull dwn gently n steering arm thus remving frm upright 8 Remve the Upper Frnt Cntrl Arm nut and blt. Carefully pull up n cntrl arms, thus remving frm upright NOTE: The slits in the upright must nt be widened using a chisel r similar tl! This can cause the pinch arms t crack. If the cntrl arm pins are stuck in the husing, tap lightly with a rubber mallet n the bttm f the cntrl arms. 9 Peel back n rubber seal and remve Nw remve plastic cver t reveal cntrl arm girdle blts 10 Remve blts caps. NOTE: These are easily remved with lng nse pliers 6 f 28

7 11 NOTE: 2 persns preferred Persn 1: Hld up damper assembly frm underneath car Persn 2: Remve 3 munting blts. Alternate evenly between all 3 12 Carefully remve entire assembly. 13 Use an adequate spring cmpressr t cmpress spring n shck assembly. NOTE: Orientatin f rubber munts and crrespnding washers upn remval f cntrl arm girdle 7 f 28

8 14 Image after remval f cntrl arm girdle. Remve OEM spring and bumpstp 15 Accurately cut tp f bump stp s final length belw dashed line is: 3 1/8 16 Install frnt lwering spring and mdified bumpstp 17 NOTE: Rtate lwer rubber spring munt s spring registers prperly n bth upper and lwer rubber munts 18 Re-install cntrl arm girdle. NOTE: DO NOT grab damper shaft with any tls while tightening the nylck nut. Reinstall using same tl as was used during remval 8 f 28

9 Installatin 1 Installatin is the ppsite f remval. When installing cntrl arms and steering arm, please nte: A) Slide steering arm int place, and tighten the pinch blt B) If pinch blt desn t g thrugh, mve arm vertically while gently pushing n blt. C) Apply blue LOCTITE n threads fr steering arm blt, then tighten. Rear Remval and Installatin Perfrm installatin f rear ARB at the same time *When perfrming cmplete Sig.Series package, remving OEM exhaust prir t ARB highly recmmended* Trque Values ARB Munting Bracket Blts, 10mm Triple Square Lwer Drp Link Blts Upper Drp Link Blts Chassis Crss Brace Blts Exhaust Muffler Hanger Nuts 29 N m 54 N m 54 N m 54 N m 20 N m 9 f 28

10 1 Befre remving any parts, jack the vehicle up, and place the vehicle n fur stable jack stands r use a prfessinal vehicle lift. 2 Supprt the exhaust and remve the tw exhaust muffler hanger nuts (ne per side), 13mm scket. 3 Gently pry the tw center exhaust rubber hangers f ff the exhaust. Use a lubricant (i.e. WD-40) if required. 10 f 28

11 4 Remve the center chassis crss brace, 16mm scket. 5 Lwer exhaust t give clearance fr remval and installatin f the ARB. 6 Lsen but d nt remve the lwer ARB drp link blts, 16mm scket. 11 f 28

12 7 Discnnect upper ARB drp link blts frm the ARB and rtate link t the side, 16mm end wrenches 8 Remve the blts attaching the ARB brackets t the subframe (bth sides), 10mm Triple Square Scket. 9 Remve the stck ARB frm the car. Gently pry ff the ARB munt brackets and rubber bushings (these will be re-used with the STaSIS ARB). OEM ARB bushings have enugh flex t accmmdate the STaSIS ARB. 12 f 28

13 11 Install STaSIS ARB int vehicle. It may be necessary t deflect the upper cntrl arm by gently using a pry bar as shwn t facilitate the installatin. 12 Once lcated, installatin is the reverse f all remval steps. Make sure t lcate drp link blts int the ARB befre tightening the ARB Munting Bracket blts. Trque all fasteners t the specificatins shwn. *NOTE*: After munting t the vehicle, make sure yur ARB is centered between the tw clamps t avid pssible binding and interference with suspensin cmpnents during vehicle peratin. 13 f 28

14 Remve wheels 1 Remve ride height sensr lever arm NOTE: Driver s side nly 2 Unscrew tw trx fasteners t partially remve inner fender liner 3 Remve lwer damper munt blt 14 f 28

15 4 Remve nut and blt fr upper anti-rll bar munt 5 Pull away inner fender liner t reveal upper damper munt blts. Lsen blts, and remve damper 6 Remve bumpstp fr mdificatin. Accurately cut tp f bumpstp s final length belw dashed line is: 4 3/4 15 f 28

16 7 Remve rear cil springs with spring cmpressr tl VAS 6274 and VAS 6274/10. 8 Install STaSIS rear spring with the spring cmpressr. NOTE: Orient the prgressive cils twards the tp 9 Install damper assembly and trque t: Upper blt: 37 ft-lbs Lwer blt: 111 ft-lb Nte Bnded rubber suspensin bushings can nly be turned t a limited extent. The munting blts f the suspensin links must nly be tightened when the suspensin is cmpressed t the curb weight psitin. 10 Install wheels and tighten. Lwer the car nt its wheels and trque all wheel lug blts t the recmmended trque. Nte: Check wheel alignment after suspensin installatin 16 f 28

17 C6 A6 Perfrmance Brakes Perfrmance Brake Kit Parts List: Qty Descriptin 1 Rtr Alcn 370X32 RH 1 Rtr Alcn 370X32 LH 4 SHCS M12x1.750x Blue 1 Caliper Alcn Mn6 RH Trailing 1 Caliper Alcn Mn6 LH Trailing 2 Bracket C6 A6 Mn6 1 Line Kit Audi Frnt Alcn 2 Brake Line Stp Washer 1 Pad Mn6 SBS Pr-Track 1 Fluid Mtul 5.1 Installatin Guidelines Trque all fasteners t specificatin. D nt use an impact wrench. The rtrs are side-specific, rtatinal directin is labeled. Open prtin f crescents face tward the directin f rtatin. The rtrs have been dynamically balanced by machining the uter edge. Flat spts alng the uter diameter are nrmal and will nt affect the perfrmance f the rtr. Tighten hydraulic cnnectins with a line wrench. Bleed brakes prperly t assure prper brake peratin; the use f a pwer bleeder is recmmended. Ensure all ABS sensr and Pad wear sensr plugs are recnnected. 17 f 28

18 Prper pad bedding is essential t prper brake peratin. Initially drive the car with lw braking frce t check brake peratin; then fllw all steps listed in the bedding prcess utlined at the end f this instructin manual. During bedding d nt thermally shck the rtrs with aggressive braking befre the rtrs have cme up t temperature. Cracks n new rtrs can frm due t thermal shck. Gradually increase brake pressures as instructed in the bedding prcedure. After bedding brakes re-trque wheel nuts t prper trque specificatins. If vibratin ccurs during nrmal usage, check fr abnrmal pad wear depsits n the rtr. Duble check all fasteners and repeat the bedding prcess 2-3 cycles until the pad depsits n the rtr becmes unifrm. If the vehicle is driven in adverse weather cnditins, STaSIS Engineering recmmends annual cleaning and inspectin f the rtr crescents. A cmmn surce f vibratin can be attributed t dirt cmpletely filling in the crescents n the inbard side f the rtrs which in turn will nt allw the pad t functin prperly. Brake rtr wall thickness wear limit is 1.0 mm per side f rtr. Rtr face runut limit +/ in, when taking measurement make sure rtr is tightened dwn t the hub at all 5 blt lcatins. 18 f 28

19 Instructins 1 Srt the parts in the brake kit fr the right and left side. Brake bleeders face upward. Caliper munting brackets are universal. Install brake pads in calipers. Install brake lines with banj blt and crush washers. Orient brake line facing straight up as shwn. 2 Raise vehicle and remve the frnt wheels. 3 Using brake cleaner, clean the brake line cnnectin at the bdy flange. Remve all dirt and debris frm this area and frm the line cnnectin threads s that n dirt will get int the new brake line when it is installed. 4 Remve the caliper. Remve the ABS sensr wire frm the hlding bracket n the brake caliper t facilitate remving the caliper. Discnnect the brake pad wear sensr wire frm the driver s side frnt brake inner pad. Remve caliper munting blts (the blts hlding the caliper munting bracket t the upright). Save these blts as they will be reused. Remve caliper and supprt it s that the brake line is nt under tensin. 5 Remve the brake rtr. Clean the hub, remving all rust frm the rtr munting surface, the rtr pilt and wheel pilt. Apply sme anti-seize t the pilt surface t prevent rtrs and wheels frm sticking in the future. D nt get any anti-seize n the rtr munting surface f the hub. 19 f 28

20 6 Install caliper munting brackets using the stck munting blts and trque t 92 ft-lb. The bracket will munt t the utside face f the upright with the machined pckets n the bracket ging against the upright. The OEM blts will fit thrugh the upright frm the backside and thread int the bracket. 7 Install the new rtrs making sure they are free f dirt and grease. Tighten the rtr retaining blt t 48 in-lbs. 8 Place the caliper with the brake pads installed nt the caliper munting bracket and install the caliper munting blts M12 x 1.75 x 60 and trque t 70 ft-lb. If the caliper will nt g ver the rtr because the pads are t clse tgether, push the pads back using a pad spreader. Nte: When rtating, the rtr must always pass the small caliper pistn first. Therefre in a trailing caliper applicatin like we have here the small caliper pistn will be at the bttm f the caliper. The purpse is t insure even pad wear. 20 f 28

21 9 Replace the frnt brake lines. Use an 11-mm line wrench n the hard line nut and a 16-mm wrench n the flats n the flex line hse-end. Remve the stck flexible line frm the hard line and cmpletely remve the stck caliper and line frm the vehicle. Install the cpper washer nt the new line as shwn. Install the new flexible line, with washer using the stck spring clip under the hard line nut and clean with brake clean nce tightened. Install the rubber brake line grmmet int the factry bracket n the back f the upright. Re-cnnect all ABS sensr wires and the brake pad wear sensr. 10 Make sure that the brake rtr spins freely and that the rtr is flush n the hub. 11 Bleed the brakes using fresh high-quality brake fluid. A pwer bleeder is highly recmmended. Tw bleeders are n each frnt caliper. Bleed the uters first until n air exits, then the inners until n air exits Wait minutes. Pwer bleed again while turning the ignitin n/engine ff and strke the brake pedal five times when each bleeder is pen. This prcess will assure a prper bleed with the ABS equipped system. Tighten all bleeders securely. 12 Clean all brake line cnnectins with brake cleaner and cmpressed air s that they are clean and dry. Start engine and pressurize brake system several times and check fr leaks at all the brake line cnnectins. Crrect any leaks befre 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. 21 f 28

22 14 Verify that all blts are tight and trque the wheel lug blts. 15 Test drive the car using the brakes gently. 16 WARNING: D nt aggressively test the brakes until they are prperly bedded. 17 Bed the pads and rtrs. See the Bedding Prcedure attached t these installatin instructins. After brakes are fully bedded recheck wheel lug blt trque. 22 f 28

23 STaSIS Bedding Prcedure After installing new pads, rtrs, r bth, it is necessary t prperly bed the pad t the rtr befre using the brakes t their full capacity. What is bedding? Bedding is the prcess f depsiting a layer f pad material (ften called the transfer layer r transfer film) nt the surface f the rtr. Brake rtrs used n OEM style brake systems d nt require this transfer layer as the braking system is relying n frictin between the pad and the rtr material t slw the vehicle dwn. On STaSIS rtrs, the bnd between the pad and the transfer layer is much strnger and the frictinal characteristics f the pad/transfer layer interface are far better than thse f a pad/rtr interface. It is therefre crucial t bed pads prperly t ensure the reliability, perfrmance, and lngevity f yur STaSIS/ALCON brake system. When shuld I bed pads and rtrs? Bedding is recmmended whenever yu install new pads r rtrs, r experience vibratins while braking. Fr new pads and rtrs, bedding allws the manufacturing resins in the pads t burn ff slwly t avid uneven depsits r pad glazing. Bedding als allws the rtrs t relieve any thermal stresses incurred during the manufacturing prcess. Vibratins felt thrugh the brake pedal are mst cmmnly a result f uneven pad depsitin, which is remedied by re-bedding the existing cmpnents. Bedding Prcess 1. Upn initial installatin d nt bed the rtrs immediately. Drive the vehicle with nrmal t light braking fr 1-2 days t allw the pad and rtr surfaces t cnfrm better befre bedding in at higher temperatures. 2. Find a suitable rad. Yu will need a relatively straight rad with minimal traffic where yu can safely (and legally!) reach speeds up t 65 MPH. 3. Once the car has been driven with light braking fr a few miles t bring the rtrs up t the prper perating temperature, bring the car up t apprximately 65 MPH. Gently apply cnstant pressure (abut 10%) t the brakes, bringing the car dwn t abut 20 MPH. 4. Accelerate briskly back t 65 MPH. Apply the brakes again, hwever this time use mre frce (abut 20%). 5. Repeat steps 2 and 3, each successive time applying mre pressure. Yur last tw brake applicatins shuld engage r nearly engage the ABS system. 6. D nt immediately stp the vehicle with yur ft n the brakes after step 5, the cncentrated heat frm the pad sitting n a nn-rtating rtr will warp the rtr. Drive vehicle using abslutely minimal brake applicatin t cl the rtrs t ambient temperature (freeway driving). 7. Once the system has cled, repeat the entire prcess. After cmpleting tw heat cycles n the rtrs, check the rtrs fr an even, slightly hazy cating (ften with a slight blue tint). Any sptting r bltches indicate uneven pad depsitin. Repeat the prcess until the rtr surface is even. 23 f 28

24 C6 A6 Perfrmance Exhaust Exhaust Kit Installatin Parts List Qty Descriptin 1 A6 Sig Series Twin Tip Exhaust Instructins Remval and Installatin 1 Stck exhaust pictured here: 2 A) Remve chassis crss brace B) Lsen clamps that cnnect stck exhaust t catalytic cnvertrs C) Slide supprt bar ut frm rubber hanger NOTE: Spraying lubricant inside rubber hanger eases remval 24 f 28

25 3 Slide supprt bar ut frm rubber hangers n bth sides. NOTE: Spraying lubricant inside rubber hanger eases remval 4 With all fasteners and clamps remved/lsened, remve entire exhaust system as a whle 5 Ready fr the installatin f new STaSIS Perfrmance exhaust system STaSIS Perfrmance exhaust shwn: 6 Start with installing the mid pipe t catalytic cnvertrs, and supprt bars int crrespnding hangers 7 Nw install passenger s side rear sectin t mid pipe, fllwed by driver s side. Make sure t install supprt bars int crrespnding hangers NOTE: Leave clamps lse enugh t allw fr adjustment 25 f 28

26 8 Reinstall hardware fr adjustable bracket and tighten flanges and bracket with mufflers aligned and spaced evenly. Cnfirm the side-side distances are equal (x). Lsen nut (arrw) n adjustable bracket and align muffler as necessary. Trque nut t 23 Nm (17 ftlb Once the crrect alignment has been achieved, trque dwn all band clamps Test drive and check fr rattles. Re-adjust as necessary t prvide prper clearance NOTE: Ensure at least 1 ½ clearance between exhaust pipes and heat shielding 26 f 28

27 Signature Series Pst Installatin Checklist Suspensin Ensure frnt and rear swaybars have been recnnected Ensure frnt and rear ride sensing actuatr rds have been recnnected Ensure all suspensin and anti-rll bar munting blts were tightened with the suspensin cmpressed t the curb weight psitin. Check ride height and alignment after driving the car fr a few miles, as the rubber bushings will cause the car t settle. Brakes Ensure all ABS sensr and Pad wear sensr plugs are recnnected Ensure brake line grmmet is prperly seated n bracket. Cycle steering frm full lck left t full lck right (with the suspensin cmpressed t the curb weight psitin) and inspect fr pssible binding n the brake line. After bleeding brakes, cycle pressure t the pedal and duble check all bleed screws and brake line cnnectins fr pssible leakage. Drive the car at lw speeds fr a few miles t check brake peratin befre beginning brake bedding prcedure. During bedding d nt thermally shck the rtrs with aggressive braking befre the rtrs have cme up t temperature. Cracks n new rtrs can frm due t thermal shck. Gradually increase brake pressures as instructed in the bedding prcedure. After bedding brakes re-trque wheel nuts t prper trque specificatins. After installatin and bleeding is cmpleted duble check brake fluid level. If vibratin ccurs during nrmal usage, check fr abnrmal pad wear depsits n the rtr. Duble check all fasteners and repeat the bedding prcess 2-3 cycles until the pad depsits n the rtr becmes unifrm. Exhaust During and after install, wipe ff all assembly and shipping particles frm the exhaust. If dust is nt wiped ff, nce the exhaust gets ht, the particles burn nt the stainless steel finish and becme permanent. Ensure the exhaust tips n bth sides prtrude frm the bumper evenly and are nt tuching any bdy panels. Apply anti seize t all assembly blts t allw fr ease f remval. 27 f 28

28 STāSIS Engineering Race Bred Adrenaline 28 f 28