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Volkswagen Golf: Golf Exhaust Makeover Oct 2, 2009

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We had a sneaking suspicion that our exhaust was extra-restrictive. The catalytic converter was rattling and the car felt pretty asthmatic at higher rpm. Turns out the converter was broken, and almost all of the internal matrix was actually stuffed inside the downstream muffler.

After we found a Techtonics exhaust system in the junkyard for $14.99, we went on the hunt for a header to match. We sourced a Techtonics race header and a new mid-pipe to complete the exhaust system from stem to stern.

The installation was pretty straightforward, taking about six hours total. The header, with its long primary branches, actually comes apart so you can install it from the top of the engine compartment. Wiggling it down from the top took some doing, but we got the job done.

Now that the exhaust is done, we’ll be scheduling some dyno time to compare aftermarket chips for the fuel injection system.

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Comments

speedblind:

Looking good. I chuckled when I noticed that your suspension travel at full droop looks close to the initial ride height pre-coilover. Any issues with suspension travel? Car looks really good.
Oct 5, 2009 11:55 a.m.

skullsroad:

I love the tipless exhaust and ITG filter. One of my favorite projects so far.
Oct 6, 2009 2:53 a.m.

Per Schroeder:

Thanks. On the suspension travel, the H&R club sport package we chose is pretty short, but has both a stiff enough spring rate and valving to be controlled but firm. We were told they were nearly an 'install and forget' item and that's wrong–so far it's install and say, “wow” at every corner.
Oct 6, 2009 4:42 a.m.

Autolex:

my girlfriends 2004 (2.0L) jetta is acting pretty similarly, the motor seems strong at low rpm's but kinda chokes as it gets above 4-4500 rpm.. could this be a similar issue? good to see the car is running stronger!
Oct 6, 2009 8:09 a.m.

leigerreign:

Hope you got that heater core problem fixed Per! The exhaust looks really nice. Hopfully ill see it back at at an autocross before the years end? (Matt Smith)
Oct 7, 2009 10:20 p.m.

sidewayz_control:

Thanks guys for the VW project car, I sometimes think they are totally forgoten, especially the Mk3. Looking forward to see all the progress, it should motivate me to finish building my 1996 Golf CL. The 1.8l econo model only available in Canada. Ok I am swaping the 1.8 for the european Mk3 2l16v (ABF engine code). Cheers! Ivan
Oct 13, 2009 9:39 p.m.

seeker589:

Per - I wanted a Jetta when I read your book and got one. Now I want a MkIII Golf/Jetta. Will I get one - only time will tell. Why do your VW project cars have this effect on me? I must be sick! The Golf looks GREAT!
Oct 16, 2009 6:50 p.m.

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Turns out the converter was broken, and almost all of the internal matrix was actually stuffed inside the downstream muffler.