Starting a new project on the Passat, involving swapping OEM R32 downpipes onto it. Here is my info from my B7 thread:
I am always in constant thought about the exhaust on this car. Been doing some thinking as of lately and revisited Devin's (DBVeeDB) Passat thread where he has some great information regarding the OEM 3.6, OEM .:R36, and OEM .:R32 manifolds, downpipes, and cats. As you may or may not know, my wife's R32 has a full Milltek system, including the manifolds. Based on some quick research, the 3.2 and 3.6 exhaust manifolds are interchangeable. One of the part numbers Devin showed on his manifold was 03H-253-032-B, which is for cylinders 4-6 on a 3.2 or 3.6 Passat, CC, and Touareg. This means, the Milltek manifolds and downpipes (with or without cats) will fit the Passat 3.6. Taking this one step further, Milltek also makes replacement downpipes which fit to OEM manifolds.
Going even one step further, haha, I have a full OEM R32 manifold back system in my garage from my wife's car. Since I don't feel like dishing out a couple grand right now, I am thinking about swapping out the downpipes. I know one of Devin's concerns was the extra set of resonators that the Passat has. I know I have already deleted them for sound restriction so I am thinking this is a plausible task. Making it easier will be not having a driveshaft in the way. Haha.
Thoughts?
Photo of the OEM .:R32 manifolds, downpipes, and cats from my wife's car:
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Link to where Devin starts going in depth:
http://forums.vwvortex.com/showthre...-my-Passat&p=80457135&viewfull=1#post80457135
you don't need to swap the manifolds, I have a mkv r32 dp on my car using the 3.6 manifolds. my concern would be how many o2 sensors you have. my swap came from an 07 which had 6 sensors but the um software only requires 4.
Oh I know. I don't feel like pulling another intake manifold (once on the R32 sucked and I have to do it again to do the SAI block off). Plan was just to just do the downpipes. As far as the sensors, I believe my Passat has four O2 sensors, same as the R32 (two on each downpipe). Major difference is location of the second sensor. It is further down stream since there is no pre-cat. Devin lengthened his sensors successfully.
As far as tunes, I am not happy. I contacted UM and Unitronic. UM essentially told me that it's not a priority to them and never replied back. Unitronic has a tune for the 2012 CC 3.6 DSG 4motion that has some serious gains. Their response was that the ECU would have to be sent to them for testing and no promises for power gains [exceeding APR's 7 hp]. I refuse to buy APR's pathetic tune. Already being in contact with my friend Chris at CBTuning (Chris contacted Unitronic for me), he recommended OE Tuning. He said Jeremy from OE Tuning would come to his shop (25 minutes from me) and bench/dyno tune the car for me for a day. It would in turn be a development car. He also stated that Jeremy laughed and promised way more than 7 hp. Haha. If he is not able to provide a DSG tune with launch control, Chris said Unitronic does have a file for that.
have you tried calling fred @um, if not call innovative motorsport and he is the front man there also. I don't see why the file I have for my car wont work on yours
I was actually speaking with Fred via e-mail. I really want UM, but if there is no motivation and willing to cooperate, I will move on. Your 3.6 is a 2007? I know not many differences were made but the manifold is the major change.
Thanks for all the shout outs! You will love the way the r32 downpipes feel on the car, I noticed a decent improvement. And I am still problem free with my extended 02's. Fuzzy is correct, certain 3.6 systems had 6 total ports, worst case scenario is you buy two plugs for the 2 that aren't used. Your passat most likely has 4.
I thought I looked up the r32/3.6 manifolds and found different numbers, so I am surprised to hear that. I figured the port opening would be larger for the 3.6. Do me a favor and measure one of each port on those 3.2's, and I will do the same with my stock 3.6 manis I have laying around.
I also noticed that the milltek and supersprint headers were offered for the r32 and r36 overseas, so i have been down this road about getting a full header system. But like you said, spend over a grand or just put the oem r32 stuff on and get some good results for a fraction of the cost. :thumbup: I am glad to see you are STILL messing with the exhaust setup. I can't stop thinking about how I want to perfect mine even more so. ANd I never get tired of hearing that vr6 love song. :heart:
I will measure the ports when I go get the setup (at my friend's storage). I am interested in the difference. The Milltek system is amazing on my wife's car. So goddamn loud. One day I will do the Milltek downpipes, but my car is still under warranty so I can't go too crazy. Haha. The wookie noise needs to be moar...moar...moar! I am looking to do this in a week or so and there will be documentation and pictures.
When I had my Ecu done he asked what manifold I had, not sure if it makes a huge difference but he did say the gray manifold was the better one
Carry on! If you want me to move this info some where else Chris, lmk. But I wanted to seize the opportunity to post it here since it was getting discussed.
I'm getting more upset now, knowing that there are several UM 3.6 tunes out there and I'm being blown off. I guess I comes down to who you know. I spoke with Jeff and Fred in person and they were singing a different tune.
I thought I remembered reading that when Jesse did the manifold swap to the Golf R36, there was the minimal upper RPM hp change. From a service stand point, I'm a fan of the two piece manifold. Removing the front on the R32 to do the full exhaust was frustrating. I think for the Passat, I'll be leaving this one on. Besides, I won't need it with a turbo kit anyway.
Devin, many thanks for all the info! It can stay because the B7 forum needs some class.
After talking back and forth with Devin, I went and took some digital measurements today of the OEM 3.2 exhaust manifolds I took off of the wife's R32. Devin also sent me photos and measurements of his OEM 3.6 exhaust manifolds. Right now, my judgement is that even though they look different, they are interchangeable. The studs line up and with the exception of carbon build up on the 3.2 manifolds, the measurements are the interchangeable. Break down:
All measurements were done on the manifold for cylinders 4-6.
- Cylinder 4 width, 3.2: 34.671 mm
- Cylinder 4 width, 3.6: 34.88 mm
- Cylinder 4 height, 3.2: 37.084 mm
- Cylinder 4 height, 3.6: 37.91 mm
- Cylinder 5 width, 3.2: 34.773 mm
- Cylinder 5 width, 3.6: 34.89 mm
- Cylinder 5 height, 3.2: 36.068 mm
- Cylinder 5 height, 3.6: 38.32 mm
- Cylinder 6 width, 3.2: 34.976 mm
- Cylinder 6 width, 3.6: 34.92 mm
- Cylinder 6 height, 3.2: 36.424 mm
- Cylinder 6 height, 3.6: 38.10 mm
- Manifold exit, 3.2: 1.747"
- Manifold exit, 3.6: 2.059"
- Pipe OD after cat, 3.2: 1.965"
- Pipe OD after cat, 3.6: 2.133"
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Ordered the downpipe gaskets and nuts yesterday:
- Gasket: 3D0-253-115-E (MSRP $12.90)
- Nut: N-102-090-09 (MSRP $0.90)
Devin let me know that the rear O2 spacers need to be lengthened about six feet. Each sensor has four wires; black, grey, and two white.
I need to do a lot of carbon cleanup on the inlet of the downpipes. Hopefully doing this on Wednesday. :thumbup: