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HHR now offers its 3rd variation of its secondary cat bypass for the first generation VW Touareg V8 (2002-2010). The stock Touareg has 2 sets of (4 total) catalytic converters and this bypass removes the rear set of cats (you will still have one full set remaining on the car) to increase HP/TQ, sound levels by a marginal amount and provide incremental weight savings.
We hand manufacture our own bypasses in Denver, Colorado. The tubing, flange, and 4 adjustable hangers are made from 304 stainless steel with a matte brushed finish. We utilize a 2.5" tube which mates up to the factory down pipe, then to the factory exhaust. Our flanges are 3/8" 304 stainless steel, CAD-designed to match factory specs and are precision waterjet cut. Our bypass also incorporates our newly added 4 independently-adjustable stainless hangers. We have consistently offered our bypasses with hangers, but decided to transition to adjustable hangers to eliminate any fitment issues and to allow consumers to adjust their bypass clearance as the exhaust sags over time. In addition, we have realized how important the role of hangers are in supporting the midsection of the exhaust. While the bypasses are considerably lighter than the factory cats, hangers are mandatory because the factory downpipes are flexible braided stainless steel and are not designed to be weight bearing. Adding bypasses without hangers will eventually damage the factory downpipes.
The factory secondary cat has tight radius bends and in order to match those bends for clearance, we took the approach of utilizing butt-welded bends. This may appear to be cheaper route to weld together small bends, but it’s the more costly and most resource intensive approach for creating the most advanced bypass for your Touareg, offered at a reasonable price. The bypass provides imemdiate addon power gains throughout the powerband with peak gains of 15hp to 17hp.
We believe this is a DIY project for anyone capable of operating a wrench. We provide detailed instructions, needed hardware and copper gaskets. This project is estimated at 90 to 120 minutes for the first-timers. It’s a 60-minute project once you’re comfortable with the process.