Author Topic: Started moding my 2005 Passat TDI wagon  (Read 2972 times)

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s4josh

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Started moding my 2005 Passat TDI wagon
« on: September 09, 2005, 12:43:12 PM »
I had Bud's Muffler Service (10th & Sante Fe) build and install an exhaust system last friday.  I had them remove all the 2.112" tube, resonator and muffler from the first flex joint all the way out.  I went to 2.5" tube with no resonator and a Aero Turbine 2525 (2.5" in 2.5" out) muffler installed at the rear muffler position.  There are no cats under the car on the TDI, they are all up at the turbo in the engine compartment, so it looks like a straight pipe.  I have to say that the Aero Turbine muffler sounds very nice, its a nice low rumble and not to loud on the TDI.  As soon as I pulled out of the parking lot I knew it was worth the cost, my turbo lag was greatly reduced.  There was a good increase to the torque and power band also.  I took it for a 68 mile drive on the highway that night and got 42 MPG with the cruse control set at 75 MPH.

On sunday I bought and installed a K&N drop-in filter and that made even more improvement in power and fuel ecomony.  I wish you could just drop the filter in on the Passats :lol:  I went on the same drive again Sunday night and was able to get 44 MPG with the cruse control set at 75 MPH again.  Before this I would get 36-38 MPG crusing at around 75 MPH.

I have been using 25-50% less throttle now during normal driving due to the increase in power and torque and have gained 6 MPG in fuel economy on my first tank on diesel.

Edit: grammer and speling * ;P

I think I am going to have to goto the next dyno day and get a baseline before I do the ECU.
Josh Ver 2.0

2011 VW Jetta 2.5 SE DSG
2009 VW Jetta TDI 6sp man
2006 VW MkV GTI DSG w/LC
2005 VW Passat Wagon TDI-PD
2003 VW Jetta TDI-PD
2001 Audi B5.5 S4 6sp man

BHase

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Started moding my 2005 Passat TDI wagon
« Reply #1 on: September 09, 2005, 01:52:32 PM »
If you don't mind me asking, how long did it take them to do that and how much did it set you back? I'm trying to get an idea of what it will cost to match some cats with appropriate flex piping to my exhaust manifold and system.

Ben
I'm not an expert in any field but drinking beer and breaking stuff so don't take my response as the best foundation for a conversation." - Jay

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Started moding my 2005 Passat TDI wagon
« Reply #1 on: September 09, 2005, 01:52:32 PM »

s4josh

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Started moding my 2005 Passat TDI wagon
« Reply #2 on: September 09, 2005, 02:05:47 PM »
I waited there and they had it done in an hour and 15 minutes.  It cost $440 with tax, the muffler being $196 and some other parts they used.  Just give them a call.  They only do exhaust systems.  The local Austin Martin and Ferrari dealers take their cars there and they do a lot of high end stuff.
Josh Ver 2.0

2011 VW Jetta 2.5 SE DSG
2009 VW Jetta TDI 6sp man
2006 VW MkV GTI DSG w/LC
2005 VW Passat Wagon TDI-PD
2003 VW Jetta TDI-PD
2001 Audi B5.5 S4 6sp man

BHase

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Started moding my 2005 Passat TDI wagon
« Reply #3 on: September 09, 2005, 02:09:49 PM »
I would give them a call, but I'm in St. Louis right now.  The $440 figure is something I had feared (but it isn't unexpected), I can't make an expenditure like that right now (on something like unnecessary tuning). :)
Thanks for letting me know!

EDIT: I just noticed that your $440 figure included the price of the parts. Woo!  Nevermind.  $440 is pretty good then.  I'm assuming the labor was something like $200?

Ben
I'm not an expert in any field but drinking beer and breaking stuff so don't take my response as the best foundation for a conversation." - Jay

aowhaus

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Started moding my 2005 Passat TDI wagon
« Reply #4 on: September 09, 2005, 03:12:29 PM »
That sounds about right.

I'm taking my car into Muffler King (which specializes in Imports).  I'm getting my stock suitcase resonator removed and getting a Flowmaster stainless steel glasspack installed in its place and a Flowmaster muffler fore of that.  The Flowmaster supposed to have a nice deep tone without being too loud (more refined sounding than the Borla exhaust).
The estimate came to about $500 parts and labor.
2008 Mercedes Benz C300 4matic Sport
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s4josh

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Started moding my 2005 Passat TDI wagon
« Reply #5 on: September 12, 2005, 02:19:05 PM »
Hey aowhaus,

Your going to have engine -> resonator (glasspack) -> flowmaster (muffler) -> exit?

I have used flowmaster mufflers on a Saab 900 Turbo (2.0L I-4) and a Jeep Cherokee Sport (4.0L I-6) both mid mounted using 2.5" pipe with no resonator and I like the way they sounded.  The 50 series isn't that load if you are still running a cat.
Josh Ver 2.0

2011 VW Jetta 2.5 SE DSG
2009 VW Jetta TDI 6sp man
2006 VW MkV GTI DSG w/LC
2005 VW Passat Wagon TDI-PD
2003 VW Jetta TDI-PD
2001 Audi B5.5 S4 6sp man

aowhaus

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Started moding my 2005 Passat TDI wagon
« Reply #6 on: September 12, 2005, 05:04:47 PM »
yup.

I was originally considering replacing the suitcase resonator with a Thrush 20" Glasspack and replace the stock muffler with a Borla Turbo muffler.  I found out that the Glasspack is not very durable and will start to deteriorate after a year, and also the Borla muffler is a little to loud and and not as deep sounding as I would like it to be.
Magnaflow makes their own glasspack that is encased with stainless steel and offers a lifetime guarantee, while Thrush and other brands only offer a 1 year guarantee.  The Magnaflow muffler produces just the right kind of sound and is very durable (also stainless steel) and offers a liftetime guarentee.
2008 Mercedes Benz C300 4matic Sport
2004 Aprilia Mojito Custom 50

BHase

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Started moding my 2005 Passat TDI wagon
« Reply #7 on: September 12, 2005, 05:22:45 PM »
Screw that. Kick out those cats, who needs 'em? :)

Ben
I'm not an expert in any field but drinking beer and breaking stuff so don't take my response as the best foundation for a conversation." - Jay

s4josh

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Started moding my 2005 Passat TDI wagon
« Reply #8 on: September 14, 2005, 12:08:28 PM »
aowhaus the way your setting it up is the best way of doing it.  I would have suggested to you to use Magnaflows MagnaPack, they are the best ones on the market.  

Magnaflow is going to be discontinueing them though (if they haven't already) :(  and there will be no more manufactures of high quality glasspacks left, I think they are the last ones.

Think green and fast BHase :p
Josh Ver 2.0

2011 VW Jetta 2.5 SE DSG
2009 VW Jetta TDI 6sp man
2006 VW MkV GTI DSG w/LC
2005 VW Passat Wagon TDI-PD
2003 VW Jetta TDI-PD
2001 Audi B5.5 S4 6sp man

ColoradoB5

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Started moding my 2005 Passat TDI wagon
« Reply #9 on: September 14, 2005, 02:25:03 PM »
I have heard Bud's is very good.  This is the second good review I have heard on them.
You can't rehabilitate a fire ant.