I finished installing my downpipes this weekend and did it myself with handtools and using a jack and jackstands, as I don't have a lift.
Keeping in mind that I'm no mechanic, everything went well in the end, but took me longer than anticipated (between 8 and 9 hours). I would imagine having a lift and fancier tools would have made it significantly quicker. An extra set of hands would have been hugely helpful in several areas as well (primarily attaching the midpipes- although straightforward, I found it annoying as I kept having one-end or the other of a midpipe sliding out and falling before I could get the clamps tightened).
Although the APR install instructions are quite good, and the pictures are all spot on, there are a few areas that I thought could have saved me some grief and some time had I known better:
1) There isn't a list of required tools. I imagine any home mechanic worth their salt has everything required at arms length, but I needed to make a run for some extension arms for my socket wrenches to get at some hard to reach places. With that said, the bare minimum tools for the job:
Socket wrenches with extension arms (6 inches would work in most hard to reach places), for nut sizes 10 and 13mm.
Torx bits or Torx screwdrivers, size 25, 30, and 50.
A pry tool for the plastic push-tabs in various spots.
A Phillips-head screwdriver for the 7 screws on the belly pan.
A 22mm wrench or oxygen sensor wrench- my 22mm wrench was way too big to fit in the tight spaces for the original O2 sensor locations, and I wound up just using a vice grip on those, which worked out ok.
Recommended:
A Vagcom cable and VCDS software to check any fault codes that arise- I had to diagnose that one of the downstream O2 sensors wasn't working because the end of its harness became detached during the install. I likely would have had a MUCH harder time figuring this out without it.
Also recommended:
1) Vibrant J shaped O2 spacers, part 11619. These are available on amazon as well as from Eurosport tuning. Mine arrived from Eurosport within 3 days of ordering them.
2) A tube of Permatex muffler and tailpipe sealant. I found (the hard way) that butt-joints between the APR downpipes and midpipes are much more prone to an exhaust leak than the OEM flange joints. Adding a 1/4" ring of this paste to the end of each downpipe completely eliminated the exhaust leaks that I found after I first completed the install.
'Trouble spots'
1) Although the pictures are technically accurate, some of them are very deceiving in my opinion. Attaching the new downpipes brackets to the downpipes and the transmission is essentially impossible to do from underneath the vehicle, as is shown in the pictures. You just can't get the supplied 13mm nuts that go onto the spring bolts in place from underneath the vehicle, unless you're a magician. It can be done by hand from above, given that the downpipes take up much less room over the transmission than the stock downpipes and cats do. This was about the only time I was glad I wasn't using a lift during the entire process.
2) Take heed on the picture regarding removing the bulkhead with the heatshield. On mine, the rubber molding on the bottom of it kept pulling off part-way, preventing it from fully re-seating later on, which led to me smelling exhaust fumes in the cabin once the install was complete, and I found that the bulkhead was not seated properly.
3) The clamps provided to attach the downpipes to the midpipes work well, but they can be a huge pain to tighten unless you have at least a 6 inch extension arm on your socket wrench- it's a very tight space to work in.
4) I found the text regarding the new wiring harnesses for the O2 sensors confusing. The bottom line is that sensors number 2 on both sides have to criss-cross over the transmission to the opposite mid-pipes, because the original stock downpipes crossed over each other behind the engine. For example, sensor number 2 on the right (passenger) originates from the right side of the engine, but has to be routed over the transmission and ultimately the sensor attaches to the left (drivers side) catalytic converter.
5) Speaking of the right (passenger's side) second oxygen sensor, the brown plastic harness connectors are really difficult to access, as the factory has them fixed with tabs to the underside of the transmission and are difficult to reach. The pictures make it look easy to access. It's not.
6) If you decide to use the J-shaped O2 spacers, attach them to the midpipes before you install the midpipes!! I learned this the hard way and had to take the midpipes back out of the car when I realized that there was no room to screw in the O2 spacers- super frustrating...
7) Strangely, the APR instructions leave out the fact that you have to re-install oxygen sensors number 1 on both sides (it goes over removing them from the original downpipes, but not replacing them back onto the new downpipes). This is easy, as they maintain the same relationship they had in the car and the same spots on the APR downpipes as they were on the factory downpipes (left sensor 1 stays on the left side, right sensor 1 stays on the right side).
Although I'm ultimately glad I did and learned quite a bit more about the overall process, it took me quite a bit longer than I had anticipated.
The good news is that I also flashed the EPL Stage 2 tune this weekend, and it has been a blast! I wound up putting a little over 100 miles on it this weekend with the new downpipes and the new tune, and thus far the O2 spacers seem to be working, as it has not thrown a CEL.
I hope this is mildly helpful, and would encourage anyone who is even minimally handy to give it a try if they are so inclined- if I can do it successfully, I'm sure everyone else here can.
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