Volkswagen Rabbit/GTI/Jetta/GLI MkV DIY & FAQ

DIY: APR downpipe install

Tools and supplies:
PB Blaster (or other penetrating grease)
Oxygen sensor wrench
1/2″ drive socket wrench
3/8″ drive socket wrench
16mm socket or 16mm wratcheting wrench
16mm deep socket
13mm socket
15mm socket
17mm socket
17mm box wrench
T20 torx screwdriver (for removing engine cover)
Jack
Jackstands
Wheel chocks

NOTE: The first few steps are EASIER TO DO if the engine is still hot.  The oxygen sensor and downpipe nuts are much less likely to be seized when they’re hot.  It can be done when the engine is cold, but it may be significantly more difficult.  When working on a hot engine, wear gloves and pay attention to what surfaces you touch.

Step 1:  Remove engine cover / intake, set aside.

Step 2:  Spray a LIBERAL amount of penetrating grease on the four nuts holding the downpipe to the turbo.

Step 3:  Locate and disconnect the O2 sensor wire.  Unclip it from the firewall so its dangling free (don’t let the plastic connector hit the hot exhaust!)

Step 4:  Slide the oxygen sensor wrench over the wire.  Using socket wrench with O2 sensor wrench, remove the O2 sensor.  Set aside (becareful, could be very hot!)

Step 5:  Remove the upper downpipe nuts.  Use the 16mm wratcheting wrench, or wrench plus regular 16mm socket to access the rear nut (blue arrow).  The front nut is a little tricky (red arrow) and you can’t see it from above.  If you use a 16mm deep socket on your socket wrench, you should be able to remove it from above without too much trouble.

Step 6: Chock the rear wheels, and jack up the front end… secure on jack stands.  You want to get the front end pretty high up, since you’ll be crawling under 2/3rds of the car to install the exhaust.

Step 7:  Get under the car, and look at the rear side of the engine.  Remove two 16mm bolts, and remove axle heat shield.  Set aside.

Step 8: Remove lower downpipe nuts.  Both can be reached using regular 16mm socket or 16mm wratcheting wrench.

Step 9:  Locate the rear O2 sensor just behind the stock cat.  Using O2 sensor wrench, unscrew from the downpipe and let hang (becareful, may be hot!)

Step 10:  Behind the cat (near the O2 sensor) you will find this frame brace held on with 4 13mm nuts.  Unscrew the nuts, remove the brace and set aside.

Step 11:  At the back end of the downpipe, locate the OEM clamp.  Loosen the two 15mm nuts on the top side, then slide the clamp up onto the stock downpipe.  At this point the rear end of the stock downpipe will be drooping and you can rest it on the rear frame brace.

Step 12:  Time to remove the last mount holding the downpipe in place.  Be ready for it to shift a little!  Remove the 2 13mm bolts holding the downpipe mount to the subframe.

Step 13:  Slide the top end of the downpipe towards the drivers side of the car, and off the exhaust studs.  Becareful not to lose the metal gasket inbetween the downpipe and turbo!

Step 14:  Work the exhaust off the turbo and out from under the car.

Step 15: Remove the downpipe mount from the OEM downpipe.  Add some grease, then pull.

Step 16: Attach the APR downpipe mount to the OEM downpipe mount.

Step 17:  Start with this piece first.  Slide it onto the turbo (making sure the gasket is still there), then install the 4 nuts.  Tighten them all up.

Step 18:  Slide the coupler/adapter and the smaller clamp onto the stock cat-back section.  You need to slide it on as far as it will fit for now.

Step 19:  Slide one large clamp onto the rear end of the cat section, and the other large clamp onto the front end of the cat section.

Step 20:  Install the cat section… insert it into the adapter/coupler on the cat-back first… then slide it over the bent pipe you already mounted to the turbo.  Slide things around until both the front and rear end of the pipe look like they are sealing.

Step 21:  Install the downpipe to subframe mount.  Tighten the two 13mm bolts holding it to the subframe, but leave the 17mm bolt holding the exhaust loose for now.

Step 22:  Position and tighten the 3 clamps.  Make sure the clamp bolts aren’t going to hit anything around them if the exhaust moves around a little.

Step 23:  Using the 17mm socket and 17mm box wrench, tighten the bolt that attaches the downpipe to the OEM mount.

Step 24:  Re-install the rear O2 sensor.

Step 25:  Re-install the frame brace using the 4 13mm nuts.

Step 26:  Lower the car off the jackstands, remove wheel chocks.

Step 27:  Re-install the front O2 sensor.  Screw it into place first… then clip the wire back onto the firewall… and re-connect.

Step 28:  Re-install engine cover / intake

Step 29:  Drive and enjoy!

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