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GLI Revival

GLI Revival

This past week we had the opportunity to work on a rare Volkswagen Jetta. “Huh, what do you mean rare, like stunt car from the Fast & Furious rare?” Okay, maybe rare is a bit of a stretch, but unique would be fair. The reason being – 2005 was the only year the MK4 Jetta came with R-line trim, suspension, wheels, body kit, & the like from factory. This eleven year old Volkswagen had less than 70,000 miles on board to boot.


The customer brought us the vehicle the same day as purchase due to the exhaust firing like an automatic rifle. The previous owner had cut out the catalytic converter, resonator, and muffler from the exhaust – although it would need a catalytic converter to legally pass a VA State Emissions Test. There are a handful of car enthusiasts that sport this aftermarket setup (albeit illegal in Virginia), but this customer was not one of them. He was more interested in having it legally pass all the DMV tests to avoid any hassles during the annual state inspections.

Heating up the stubborn downpipe bolts on the 2005 Volkswagen Jetta GLI

Heating up the downpipe bolts


He was also planning to run performance tuning down the line, so we opted for a performance exhaust. We turned to the professionals at 42 Draft Designs, in Millersville MD for their knowledge in the performance world. For this vehicle, they recommended a 3inch diameter downpipe from the turbo, and (more…)

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