AUTOTECH 10.430.217K-218K User manual

AUTOTECH
Phone [phone] Fax [phone]-E Paseo Adelanto, San Juan Capistrano, CA 92675
www.autotech.com
Part Number: 10.430.217K - 218K
Description: ClubSport® Upper Stressbar for Golf 4 and Jetta 4 incl. R32
TOOLS REQUIRED: PARTS LIST:
1. electric drill 1. one stressbar, assembled
2. 3/16” & 5/16” drill bits 2. six 5/16" AN bolts (AN5-7A)
3. hex wrenches, 1/2" & 9/16” 3. twelve 5/16" AN washers
4. socket wrenches, 1/2" & 9/16” 4. two 3/8" AN bolts (AN6-11A)
5. scratch awl or metal scribe 5. four 3/8" AN washers
6. hammer &/or centerpunch 6. two 3/8" AN nylock nuts
7. jack and wheel stands 7. six 5/16" AN nylock nuts
8. wheel lug wrench
Notes: Cars with ABS brake systems may have to either drill one small additional hole into each strut ring, or
remove the small studs that hold the connector in place, then re-mount the connector after the stress-
bar is installed. Many Autotech stressbars have a small dimple in the crosstube. This is not a defect! It
is made using a hydraulic press and is for clearance of certain engine components.
Procedure:
1. Lift your car's hood. Trial fi t the stressbar to your
car as shown (fi g 1) at right. When properly installed,
the stressbar crosses over the engine compartment at
the front of the strut towers. To properly center the
rings on each strut tower, adjust the rod end in or out
to increase or decrease the bar's width. This is the time
to check for ample clearance of the bar in the engine
com part ment.
2. With the bar on the vehicle, use a scribe or awl to mark
the three hole locations in each tower (fi g 2). Note that
you will use only three of the six holes available in
each ring. Use the guide below-right for hole locations
to use. Be sure to re-check the marks, then remove the
stressbar. (cont >)
right side left side
front of car
Holes to use:
fi g 1
fi g 2
Installation Instructions

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3 Remove the top strut nut so as to allow the strut to ‘fall’ away from the strut tower as the car is lift-
ed (fig 4). This will allow easier access beneath the towers when attaching the stressbar. This will not affect
your front end alignment settings.
4. Jack up the car and place it on jackstands so that the front wheels are off the ground. Remove both front
wheels. Using first the 3/16" bit, drill the six pilot holes in the towers. Then, using the 5/16" bit, enlarge the
holes to their final size (fig 5). There might be some body sealing adhesive that partially covers these holes. If
there is, it can be cut or pulled out of the way.
5. Unbolt each strut ring from the stressbar crosstube.
6. Using the six 5/16" AN bolts, the twelve AN washers, and six 5/16" AN nylock nuts, attach each strut ring to
its tower, using a washer under the bolt head and under each nut. Figure 6 shows the underside of the strut
tower with one of the 5/16” bolts coming down throught its hole. These bolts and nuts use a 1/2-inch wrench
size. Make sure you do not overtighten the nuts (Fig 6A) as they only require 8 to 9 ft.lbs. of torque.
7. Put your wheels back onto the car and lower the car back to the ground.
8. Re-attach the top nuts to the front struts, and torque to factory specs. (cont >)
fig 4 fig 5
fig 6 fig 6A

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9. With the car on a level surface, so as not to deflect the chassis in any way, attach the fixed end of the cross-
tube to the strut ring with the 3/8" AN bolts supplied (fig 7). Do not tighten this end yet.
10. Now, adjust the crosstube’s length so that the bolt inserts straight through the strut ring and rod end
holes (fig 8).
11. Using a 9/16" wrench, "snug" the jam nut against the crosstube (fig 9). Torque is approx 8 ft lbs.
12. Now, using 9/16" wrenches, tighten both 3/8" AN bolts and nuts that hold the crosstube to the rings. Torque
to 8 ft lbs.
(end)
fig 7 fig 8
fig 9