Passat 3.2 FSi - Exhaust flexi's

[Ben Kenobi]

Has anyone here got a fix for blowing exhaust flexi's that doesn't require a mortgage - VW's price for the part is eye watering.

You'd think that they have a repair part but oh no - they want you to buy the whole front section including a pair of CAT's - ludicrous - wasteful - and profiteering - ...

Going to check out Powerflow and see what they can do, I'd welcome any other suggestions, don't mind driving somewhere if I can get a fix for sensible money. Right now one of mine is blowing but I want to sort it before it goes completely.

Used the search and didn't find much so I'm guessing the 3.2 isn't exactly common.

[Crasher]

I weld my own in using stainless MIG, the brand I use is Ilok. They come in a huge array of lengths and bore sizes.

[Ben Kenobi]

I haven't struck an arc in 20+ years, no longer inclined toward rolling around under cars, of course if you're up for it there would be beer tokens available. I just remember from the past the hassle oft had getting exhausts off, and the lack of a 4 post lift doesn't incline me to try - from the centre box forward it is all one piece - no joints of any kind till you hit the manifold. Getting that out even on ramps would be a challenge.

[Crasher]

Not beer tokens I am afraid, a proper bill including VAT......

[Ben Kenobi]

Not put off, how familiar with the 3.2 B6 - definitely do-able? - typical price - pm me if that's best

[Crasher]

VW is my bread and butter day to day work for the last 33 years VW Audi Seat Skoda Specialists | Parts Service Modifications but as you know your car is rare and we have not done one. We have done two A3q 3.2V6's and a number of Golf 5 R32's and these are identical. The pipe would have to come out of the car to be done and you would be daft not to do both flexi's.

In the past we have only fitted new front pipes/cats as the flexi on these is very long so I will have to investigate. When they come new the flexi has a huge plastic tube clamped around it with strict instructions that the tube must not be removed until the pipe has been installed. Bearing that in mind, one new pipe we had supplied came with both ends flopping around in the wind like a, err, well, you know what.... We complained and asked for a replacement only to be told no UK stock and no German stock!



A year or so back, an A3 quattro 3.2 FSI V6 we did came back a few days later with the engine MIL on. The code was an inefficient right cat which we assumed would be a faulty post cat lambda sensor but two days later it came back again. When I looked really closely and stated to analyse the problem deeply I noticed that the weld around the top of the flexi coupling wasn't totally finished off, there was a tiny pin hole. When I shoved a windscreen washer jet cleaning tool into the hole, it went right through so the tiny hole was allowing air to be drawn in before the cat which upset it. The car then had to go to Audi to be checked (the terms of TPS supply dictate this) and they had to fit a new full front pipe under warranty as Audi would not let them weld the hole up.

So yes, been there, done that, got the scars....

[Ben Kenobi]

Could you explore and let me know, I trust your judgement, I'm concerned that if I allow an aftermarket build that they won't use a flexi similarly flexible - or long and that could do damage elsewhere. I'm getting quoted almost as much for a custom build with sport cats as a VW one - question is which way to go - since the aftermarket would be a stainless system.

As a side note what are the chains like on these - good / bad - I've read a few bad reports re the Audi but that isn't the same engine, there are no noises / rattles or otherwise right now - the high pressure pump is ticking but I believe this is normal.

[Crasher]

Think of it as an R32, it is the same engine. The chains do go but it is nowhere near the same issue as on the Audi V6, keep the oil changes to 10K miles and it should get to 130K ish before the chains start sizzling and need doing. Thankfully it is not the nightmare that they are on the Audi but it is still box out.

Stating with measuring the pipe diamter and the couplings overall length, a replacement can then be found, these people offer a good range http://exhaustpartsuk.com/index.php?...bdcb7d7dd43da0

[Ben Kenobi]

Appreciate the input, still prepared to let you do it - I've been to a couple of places today and both are talking between £600 and £800, neither inspired confidence though. I did get chance to look at it and it isn't 'mega' bad, but somebody has gooped it all up with some sort of repair paste, it's in no danger of breaking off, the rest of the systems in really good condition (from the outside) so that makes it more frustrating.

What would you go for oil wise ? - in the 2.0TDi I religiously use Shell Helix, I'm tempted to switch to Castrol Edge - I don't buy cheapo oils etc. Although the car has a full history I plan to change all the fluids anyhow, my first target is the Haldex - there is no record of it ever being changed - no ticks in the boxes - and yet it is a full main dealer service history, the DSG was done 30,000 miles ago, the engine just done.

I'm really starting to like DSG a lot, car sounds and drives really well, it deserves some TLC, and if the R32 has the same mechanicals it must be mental on the road - I tried sport mode for the first time in anger today - - really wasn't prepared for how good DSG really is.

[Crasher]

I would use Quantum Platinum in that or Castrol Edge, which is the same thing. I strongly suggest you do the DSG oil and filter at 50K and don't forget the Haldex.