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Discussion Starter · #1 ·
Well here it is guys one of the first GHL turbo back 3" system installs, broken down with complete step by step photos as a guide.
Tools Needed:
13,14,16, & 22mm wrenches/sockets
Flat blade screwdriver
Penetrate lubricant
Install Time 1.5 - 2 hours

The complete GHL 3" system, its shown here without the center resonator pipe which will be included with every kit.

The stock system, its decent but has typical VW crimps in the wrong places and the pre-cat on the downpipe is a BIG bottle neck.

The stock system , here you can see its weak points

First thing to do is remove the two 16mm bolts holding the passenger side axle's heat shield, you'll need to remove this to gain total access to the downpipe.

You now have access to the four bolts holding the downpipe to the turbo, the three visible bolts are easily removable with a 16mm wrench or socket.

The fourth bolt, is quite difficult to access and remove, the ideal tool here would be a 16mm stubby ratchet if you want to get one ahead of time I'd recommend it, otherwise a shorter wrench or adjustable ratchet can do the job, although it'll take longer.
9/4 Install Update: Its far easier to access both of the top two bolts by simply removing the airbox from the engine bay, then by brail you can reach the inner top bolt and get some decent leverage on it

Remove the front bank 02 sensor with the downpipe, unclip its harness as shown here, there's also two harness retaining clips shown here.

Next remove the downpipe support bracket (two 13mm bolts shown here)

Next unbolt the rear 02 sensor from the downpipe, counter twist the wiring harness before unscrewing (reverse for the reinstall) This will prevent damaging the wires.

Remove the two cross support brackets for easy removal of the downpipe.

Next unbolt the factory DP/Mid-pipe coupler and slide it forward onto the downpipe, separating the two factory pieces of the OEM exhaust.

Now you can remove the stock downpipe, careful this is a very flexible downpipe, don't let it get away from you and conk you in the head as your removing it!

Install the front bank 02 sensor on the new GHL downpipe, you can also remove the rear section of the stock exhaust. You wont be re-using the passenger side rear hangar so just remove it with the exhaust system.

Starting with the downpipe install the new GHL system, its bolts up much easier than the stock downpipe but that inside top bolt is still tricky. When installing the under axle pipe take care that you position the pipe to give yourself maximum under axle clearance, this will help you avoid exhaust rattles.

Awesome!


Check all of your piping alignment to make sure you don't have any potential rattles, you can rock the motor back and fourth, shake the exhaust back and fourth, push it in from the tailpipe, those are all great ways to make sure your not going to have any rattles once it's on the street. Once you're happy with the fit install the band clamps provided with the kit.

Take it out for a spin! The system makes some real wheel horsepower, it added quite a bit of response to our APR chipped GTI. We'll have some in car, drive-by, and idling sound clips next week.
http://****************.com/smile/emthup.gif
Dean
Edit Download the audio clip here right click save.



Modified by Dean F at 5:54 PM 9-4-2006
 

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Re: (theskippur)

Quote, originally posted by theskippur »
in comparing it to the stock setup, there is hardly anything to muffle the exhaust sound. How much louder is it?


I was wondering exactly the same thing.....there is hardly any muffling left?
 

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Re: Futrell Autowerks: GHL 3" Turbo Back GTI System Install How-To (Dean F)

Quote, originally posted by Dean F »
Take it out for a spin! The system makes some real wheel horsepower, it added quite a bit of response to our APR chipped GTI.
Dean


Have you guys dynoed it yet? With and w/o APR or just with APR?
-Adam
 

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Discussion Starter · #10 ·
Re: Futrell Autowerks: GHL 3" Turbo Back GTI System Install How-To (Smoltz)

Quote, originally posted by Smoltz »


Have you guys dynoed it yet? With and w/o APR or just with APR?
-Adam

No the car only has 400 miles on it, we'll wait until 1000 to start running it on the dyno. The GHL production system will have a resonator, the non-resonated center pipe (as shown) is a optional piece, and yes its pretty loud!
RE: Sprngs, those are H&R coilovers
 

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Re: Futrell Autowerks: GHL 3" Turbo Back GTI System Install How-To (Dean F)

Did you get any sound clips yet? Is it deep, buzzy, what?
Remember: Say Vhat!
 

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????? center resonator, im pretty sure that exhaust is the exact one im getting. Jeff told me there is only one resonator. I dunno i guess ill just have to wait and find out when the man in brown drops it off
 

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Re: Futrell Autowerks: GHL 3" Turbo Back GTI System Install How-To (Ghl Motorsports)

I just noticed the diff between GLI and GTI
GLI, IIRC from being under there many times, the exhaust goes above the rear "axle".
The GTI goes under the axle.
You can see the shield above the hid leveler, and can make out the exhaust pipe above that.

Maybe it's old news, but I just noticed that from this awesome writeup!


Modified by syntrix at 10:37 AM 3-4-2006
 
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