Why Upgrade to an AWE Tuning Exhaust on Your Audi RS5

The Audi RS5 is already a formidable machine, powered by a high-revving V6 or V8 depending on the generation, but its factory exhaust system is designed to meet noise regulations and production cost targets rather than deliver pure sonic excitement. Installing an AWE Tuning Exhaust System transforms the driving experience by unlocking a deeper, more aggressive exhaust note while also reducing backpressure and improving exhaust flow. The result is not just a better sound but measurable performance gains, including a modest increase in horsepower and torque across the rev range. AWE Tuning is widely regarded as one of the top aftermarket exhaust manufacturers for German vehicles, and their systems for the RS5 are engineered to bolt directly to the factory mounting points, which simplifies installation and ensures a precise fit. This guide will walk you through the entire process, from gathering your tools to firing up the engine for the first time with the new system installed. Whether you are an experienced DIY mechanic or a motivated enthusiast tackling your first exhaust swap, these instructions will help you achieve a clean, leak-free installation that will last for years.

Tools and Materials Needed

Before you begin, assemble all the required tools and components. Having everything within reach will prevent unnecessary trips to the toolbox and reduce the risk of mistakes caused by rushing.

  • Socket set – A 3/8-inch or 1/2-inch drive metric socket set ranging from 8 mm to 19 mm. The most common fasteners on the RS5 exhaust system are 10 mm, 13 mm, and 15 mm.
  • Torque wrench – Critical for tightening clamps and flange bolts to factory specifications. Over-tightening can strip threads or crush gaskets; under-tightening can cause leaks.
  • Pliers – A pair of sturdy locking pliers or exhaust hanger removal pliers will make quick work of the rubber hangers.
  • Jack and jack stands – A low-profile floor jack and a set of four jack stands are mandatory. Never work under a vehicle supported only by a jack.
  • Penetrating oil – Apply to rusty bolts and hanger studs an hour before starting to ease removal.
  • Safety goggles and gloves – Exhaust systems accumulate road grime, rust, and sharp edges. Protect your eyes and hands throughout the job.
  • AWE Tuning Exhaust System – Verify that the kit matches your specific RS5 model year. AWE offers different configurations for the B8, B8.5, and B9 generations.
  • Replacement gaskets – While the AWE kit typically includes new gaskets, it is wise to have a spare set of downpipe-to-exhaust gaskets on hand in case the originals are damaged during removal.
  • Exhaust assembly paste – Optional but recommended for sealing slip joints if your AWE system uses them.

Preparation Steps

Proper preparation is the difference between a smooth installation and a frustrating one. Take the time to set up your workspace and vehicle correctly.

  • Park your Audi RS5 on a flat, stable surface inside a garage or on a paved driveway. Concrete is ideal because it provides a level, solid base for jack stands.
  • Allow the exhaust system to cool completely. The exhaust components can reach temperatures above 500 degrees Fahrenheit during operation. Attempting removal on a hot system risks severe burns and can warp flanges.
  • Disconnect the negative terminal of the battery using a 10 mm wrench. This prevents accidental activation of the adaptive suspension or the electronic parking brake while the vehicle is elevated.
  • Remove any loose items from the trunk and rear seat area. You will need unobstructed access to the underside of the vehicle.
  • Spray penetrating oil on every exhaust hanger stud, clamp bolt, and flange nut. Allow the oil to soak for at least 15 minutes before you begin applying force.

Removing the Stock Exhaust System

Removing the factory exhaust is the most labor-intensive part of the job. Work methodically and support the exhaust as you disconnect each section to prevent it from dropping suddenly.

  • Jack up the rear of the vehicle at the designated lift points and place jack stands under the subframe or pinch welds. Never rely on the jack alone. Lower the vehicle until its weight rests securely on the stands.
  • Locate the four rubber exhaust hangers that support the rear muffler section. Using pliers, compress the hanger ears and slide them off the metal studs attached to the exhaust. If the hangers are stubborn, apply additional penetrating oil and work them with a flathead screwdriver to break the bond.
  • Identify the band clamps securing the exhaust to the downpipes just behind the catalytic converters. These clamps are typically 13 mm or 15 mm hex bolts. Loosen them completely but do not remove them yet.
  • Slide the rear section of the exhaust off the downpipe extensions. You may need to wiggle the assembly side to side to free it from the hangers. Have an assistant support the weight while you clear the hangers.
  • If your RS5 is equipped with an electronically controlled exhaust valve, unplug the electrical connector near the valve actuator before fully removing the system. Tuck the connector aside.
  • Remove the stock exhaust from under the vehicle and set it aside. Be careful not to scratch the bumper or diffuser as you slide the exhaust out.
  • Inspect the downpipe flanges and replace the gaskets if they show signs of compression loss or damage. The factory gaskets are single-use and should ideally be replaced whenever the joint is disturbed.

Installing the AWE Tuning Exhaust System

With the stock exhaust removed, you can now lay out the AWE components and begin assembly. AWE systems are designed to be installed in sections, which simplifies handling and alignment.

  • Begin by loosely assembling the AWE exhaust sections on the floor. Connect the mid-pipe to the rear muffler section using the supplied band clamps. Do not fully tighten any clamps yet; leave them finger-tight to allow for adjustment.
  • Place the assembled exhaust under the vehicle. Slide the front end of the mid-pipe onto the downpipe outlets. Apply a thin layer of exhaust assembly paste to the slip joints if your kit includes them, but be careful not to use so much that it squeezes out and hardens inside the pipe.
  • Align the exhaust tips with the rear bumper cutouts. This step is critical for achieving a symmetrical, professional appearance. The AWE system should sit centered with equal gap on both sides. Adjust the position of the rear section by sliding it left or right at the hanger mounts.
  • Slide the rubber exhaust hangers onto the AWE system’s hanger studs. AWE uses the same hanger positions as the factory system, so the studs should align directly with the existing hanger mounts on the vehicle. Use pliers to push the hangers fully onto the studs.
  • Secure the exhaust to the downpipes using the provided band clamps. Position each clamp so that the bolt is accessible for future adjustments. Tighten the clamps to approximately 35-40 lb-ft using a torque wrench. Do not exceed the recommended torque, as this can crush the pipe or strip the clamp threads.
  • Double-check the alignment of the exhaust tips. After tightening the downpipe clamps, the exhaust should not move freely. If the tips are off-center, loosen the downpipe clamps, adjust the position, and re-tighten.
  • Tighten all remaining band clamps on the mid-pipe and rear section connections. Work from front to back, ensuring each joint is snug but not deformed.
  • Reconnect the electronic exhaust valve wiring if your RS5 has active exhaust. The AWE system typically uses the factory valve actuators, so the connectors should plug directly into the new system without modification.

Finalizing the Installation

The installation is nearly complete, but the final checks are essential for safety and performance.

  • Reconnect the negative battery terminal and tighten it securely.
  • Start the engine and let it idle. Immediately listen for any metallic rattles, hissing sounds, or excessive vibration. A small amount of smoke or burning smell from the exhaust coating is normal during the first heat cycle.
  • Inspect every joint and flange for exhaust leaks. You can use a handheld mirror or a piece of cardboard to detect leaks by feeling for puffs of air. Alternatively, spray a soap-and-water solution on the joints and look for bubbles. Tighten any clamps that show signs of leakage.
  • Raise the vehicle again and perform a final torque check on all clamps and hanger bolts. The heat from the engine will cause some fasteners to expand and contract; re-torquing after the first warm-up ensures long-term security.
  • Lower the vehicle from the jack stands and go for a short test drive. During the drive, vary the engine speed and listen for the exhaust note under load. AWE systems are known for a deep, refined tone without drone at highway speeds. If you notice excessive interior resonance, check that all hangers are properly seated and that the exhaust is not contacting the underbody.

Post-Installation Tips

Your new AWE Tuning exhaust will continue to improve as the system accumulates heat cycles and the packing material in the mufflers settles. Follow these guidelines to maximize the lifespan and performance of your investment.

  • Inspect regularly – Every few thousand miles, crawl under the vehicle and check all clamps, hangers, and welds. The high heat and vibration of daily driving can gradually loosen fasteners.
  • Keep it clean – Road salt, moisture, and debris can accelerate corrosion on stainless steel tips. Wash the exhaust tips with a mild cleaner and a soft cloth after each wash. For deeper cleaning, use a stainless steel polish to restore the original luster.
  • Monitor the sound – If the exhaust note becomes louder or develops a tinny quality, inspect the packing material in the mufflers. Loose packing can shift during aggressive driving. This is rare on AWE systems but worth noting.
  • Consider a professional inspection – After the first month of driving, schedule an inspection at a trusted independent shop. A professional can verify the alignment, check for leaks, and confirm that the system is not rubbing against suspension components or the driveshaft.
  • Don’t skip the break-in – Allow the exhaust system to go through at least 500 miles before subjecting it to sustained high-rpm driving. This heat-cycling process helps the metal expand and contract uniformly, reducing the risk of stress cracks at weld joints.

Frequently Asked Questions

Will installing an AWE Tuning exhaust void my Audi warranty?

The Magnuson-Moss Warranty Act prohibits a manufacturer from voiding a warranty solely because an aftermarket part was installed. However, if the aftermarket part directly causes a failure, the repair may not be covered. For example, if the exhaust hanger breaks due to improper installation, that specific repair would not be covered under warranty. Most dealers are reasonable about this, but keeping documentation of the installation and using quality parts like AWE Tuning helps protect your coverage.

Do I need a tune after installing the exhaust?

No, a tune is not required for the AWE Tuning Exhaust System. The system is designed to work with the factory engine control unit. However, pairing the exhaust with a quality ECU tune from a reputable company like APR or Unitronic can unlock additional horsepower gains by optimizing the air-fuel ratio and ignition timing for the improved exhaust flow.

How long does the installation take?

For a first-time installer working with basic hand tools, plan for three to five hours. Experienced mechanics can complete the job in under two hours. The most time-consuming steps are removing the rusted hangers and aligning the tips perfectly.

Will the exhaust pass emissions testing?

Yes, AWE Tuning systems are designed to retain the factory catalytic converters. As long as your downpipes remain stock, your RS5 will continue to pass visual and tailpipe emissions tests in all states. If you upgrade to downpipes in the future, you may need a tune to clear the check engine light caused by the secondary oxygen sensors.

For additional technical specifications, sound clips, and model-specific fitment notes, visit the official AWE Tuning website. The Audi enthusiast community is also a valuable resource; forums like Audizine and RS6.com have dedicated RS5 sections where owners share installation tips, torque specs, and sound comparisons. If you are sourcing tools, GearWrench offers affordable, high-quality socket sets and ratchets that are well-suited for automotive exhaust work. Finally, if you prefer a visual walkthrough, search for AWE RS5 exhaust installation videos on YouTube to see the process performed on a car identical to yours.

Final Thoughts

Installing the AWE Tuning Exhaust System on your Audi RS5 is one of the most satisfying modifications you can make. The sound improvement alone transforms the character of the car, making every drive feel more eventful. By following this comprehensive guide, you can complete the installation with confidence, knowing that every clamp is tight, every gasket is sealed, and every tip is perfectly aligned. The combination of AWE’s engineering and your careful installation will deliver years of reliable, spine-tingling performance.