ffiNsAl Certification

ECE TYPE-APPROVAL CERTIFICATE

Communication concerning the approval (or extension or refusal or withdrawal of approval or production
definitely discontinued) of a type of replacement silencing system or component of the
said system pursuant to Regulation No.59.

Approval No: 824 59R-000003 ExtensionNo: N/A.

t. Trade name or mark of the silencing system: Milltek Sport

2. Type of silencing system: VW GOLF GTi

Replacement silencing sy stem

3. Manufacfurer's name and address: MILLTEK SPORT

Units l-3
Beffield Industrial Estate
Ilkeston
Derbyshire, DE7 9Da
United Kingdom

4. If applicable, name and address of manufacturer's representative: N/A

5. Brief description of the silencing system (witlr/without fibrous equipment): without fibrous equipment,
middle silencer oval, 212 x 131x
300mm long, absorbtion principle
rear silencer oval, 258 x 136 x
550mm long, inla pipe O 70mm
and two outlet pipes OSImm, which
terminate with a tip OI00mm

6. Trade name or mark of the vehicle type for which the silencing system is
intended: VTry GOLF GTi

7. Vehicle type, starting from serial number: e)

8. Kind of engine: positive-ignition, compression ignition: r)
49.49aU.474.1.2
CT-1 1-58 Rev I Page 1 of 2
Approval No: E24 59R-000003 Extension No: N/A.

9. Cycles: two-stroke or four-stroke: (.)

10. Cylinder capacity: e)

11. Engine power (kW ECE): r)
12. Number of gears: (.)

13. Gears used: (-)

14. Final drive ratio: (.)

15. Maximum power: (.)

16. Load conditions of vehicles during test: (*)

17. Sound levels

-vehicle in motion: (*) d,B(A).
-at steady speed before acceleration (*)kn/h
-vehicle stationary (*) dB(A).
-with engine running at:: (*) r.p.m.

18. Value of the back pressure: e)

19. Silencing system submitted: For approval on: 30.07.2009
For extension ofapproval on: N/A

20. Technical service responsible for carrying out the tests: fUV nheinland Italia S.r.l

21. Date of report issued by that service: 16.11.2009

22. Number of report issued by that service: 55 0323 09,vers.0

23. Approvalgranted/refosed: granted

24. Position of approval mark on the vehicle: Afftxed on under side of silencer

25. Place: Dublin

26. Date: 'ffiNsAi I/h November 2009

Certification
27 Signature:N\W TRANSPORT
DEPARTMENT

28. The following documents, bearing the approval number shown above, are annexed to this communication:
........drawings, diagrams and plans of the silencing system
........photographs of the silencing system
. . . . . . ..list of components, duly identified constituting the silencing system

Remarks: (*) : see Test Report for details

NSAI, I Swiftsquare, Northwood, Santry, Dublin 9, Ireland. Telephone: (+353+1) 807 3800, Facsimile: 01-807 3844

49.49aU.474.1.2
CT-l 1-58 Rev I Page 2 of 2
PrUfbericht Nr.: 55 0323 09, Ausf. /vers.0
Test Report No:
ECE-R59
Hersteller/Manufacturer: Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK TUVRheinland
Typlrype: VW GOLF GTi

TEST REPORT
Uniform provisions concerning the approval of replacement silencing systems

EGE Regulation No.59

Amend.03

Approval Status

ECE approval : ECE Regulation 59 - Replacement Silencing Systems

Genehmigungsstand
Approvalsfafus

Genehmigungsnummer
Number of approval

EG TEC
E24 59R-00 0003

(aDoroval number allocated in advance)

The Test Repoft shall be reproduced and published in full by the client only. lt shall however
be reproduced paftially with the written permission of the Testing Laboratory only.

TUV Rheinland ltalia S.r.l. Priifl aboratoriu m / TEsr LABa RAToRy Seite I eage
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PrUfbericht Nr.: 55 0323 09, Ausf. /verc.0

A-
Test Repoft No.:
ECE-R59
Hersteller/Manufacturer Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK TUVRhoinland
Typlrype: VW GOLF GTi

0. General information (Silencing System)

0.1. Make (trade name of the

Silencer manufacturer) : Milltek Sport

0.2. Type : Replacement Silencing System

0.3. Category of vehicle : M1

0.4. Name and address of the

manufacturer : MILLTEK SPORT
Units 1 - 3
Belfield lndustrial Estate
llkeston
Derbyshire,
DE7 8DU
United Kingdom

0.5. No. of the information document 5550323-09-00

- Date of issue : 16-11-2009
Date of last change : ---

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E24 sgR-OOOOO3
PrUfbericht Nr.: 55 0323 09, Ausf. /vers.0
Iesf Reporf No.;
ECE-R59
Hersteller/Manufacturer: Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK fUVRtrointafrb
Typlrype: VW GOLF GTi

1. Tested vehicle(s) / object(s)

1.1. Description

1.1.1. Testvehicle :VWGolf GTi

Type(s) /variant(s) /version(s) : 1K

ldent. No. (VlN) : VI|\ANZZZ1KZ9W57058O

Engine type . CQZ

Axle ratio tested : 3.389

Used test weight (kg) : 1502

1.1,2. Vehicle equipment
(Standard) : Standard OE Fitment

Mufflerl :VWAG1K0.120CJ
Muffler 1 '.
VW AG 1 KO 1 197

Air intake system / air filter : OE FIT

Type/identification :-
Insulation engine compartment /
at the engine : lnsulation in engine hood

Description of tyre type

used for testing .22514O1R18 92 Y - Bridgestone Potenza

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E24 sgR-OOOOO3
PrUfbericht Nr.: 55 0323 09, Ausf. / vers. 0
Test Report No.:
ECE-R59
Herstel ler/ M anufacture r. Milltek Sport Ltd. /6\
Derbyshire, DE7 8DU, UK TUVHheinland
Typlrype: VW GOLF GTi

2. Test record

2.1. Equipment for measuring and

testing : The test facilities / measurement equipment
used were in compliance with the test
requirements.

Measuring instruments
Speed measurements : Electronic tachometer with digital reading
accuracy: + 1o/o

Acoustic measurements . Precision sound level meter of the type

described in Publication 179 ,,Precision sound
level meters", second edition, of the lnternational
Electrotechnical Commission (lEC).

Manufacturer : BrUel & Kjar, Kopenhagen / Denmark

TYPe . 2231,2145 & 4189

2.1.1. Specifications for the test site : Test track complies with Annex lV of Directive
96l2OlEC. Certificate: PO 301 1 683-1

Test site
(su rface characteristics) :Asphalt, dry

Temperatures (Standard Silencing System)

Temperatures of
ambient air ["c] . 17.5

Temperature of test track

Surface ["C] : 21.7

Atmospheric pressure [kPa] :1009

Humidity lo/ol :76

Wind speed Im/s] :5.4

Wind direction t-1 :(SW)

Background noise [dB(A)] :42.0

TUV Rheinland ltalia S.r.l Pr0fl aboratori um / TEsr LABa RAToRy Seite I page
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 Nr.:

A
PrUfbericht 55 0323 09, Ausf. / Vers. 0
Iesf Reporf No.:
ECE-R59
Hersteller/Manufacturcr Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK rtlvRtreinta8o
Typlrype: VW GOLF GTi

Tem peratures (Milltek Silencing System)

Temperatures of
ambient air ['C] : 18.8

Temperature of test track

Surface ['C] :21.7

Atmospheric pressure [kPa] : 1010

Humidity lVol :54
Wind speed [m/s] :2.4
Wind direction t-l : EAST
Background noise tdB(A)l :42.0

TUV Rheinland ltalia S.r.l. Pr0fl aboratori um / TE sr LABoRAToRy Seite I Rage

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(Vorlage: REV.o)

E24 59R-000003
 Nr.:

A
PrUfbericht 55 0323 09, Ausf. /vers. O
Test Repoft No.:
ECE-R59
Hersteller/Manufacturer Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK TUvRheinlaPd
Typlrype: VW GOLF GTi

2.2. Test results

() numbering according to Annex l, Appendix 2 of the Directive 701157|EEC

I] numbering according to Annex 1 of ECE Regulation 51
t) numbering according to Annex 9 of ECE Regulation 51
< > numbering according to ECE Regulation 59

Remarks concern ing extension :

[The vehicle type has been tested according to the modification(s) mentioned
in item Appendix 0.1

[The new parts meet the requirements.]

[The results of the previous test(s) are still valid.]

Test conditions

METHOD A M5 A4 CVT

2nd gear, not more than 4 forward gears

2nd and 3rd gear, more than 4 foruvard
gears
automatic gearbox with manual selector xx
positions
automatic gearbox w/o manual selector
several gears
n=YoS v= km/h
v = 30 km/h
v = 40 km/h
v = 50 km/h
v = Ta vmax. = km/h
95 % fuel feed
vA-A = 60 km/h max.
vB-B (3rd gear) = km/h
n=TzS v= km/h
v= km/h

TUV Rheinland ltalia S.r.l. Pr0fl aboratori um / TEsr LABI RAToRy Seite I eage
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(vqlage: REV.o)

E24 59R-000003
PrUfbericht Nr.: 55 0323 09, Ausf. / Vers. 0

A-
Test Repoft No.:
ECE-R59
H erstel ler/ M a n uf actu re r. Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK TUVRheinland
Typlrype: VW GOLF GTi

{8.3.1 .} Tyre manufacturer : Bridgestone

{8.3.2.} Commercial description(s) of

of the type of tyre (by axle),
(e.9. trade name, speed index
load index) :22514O1R18 92 Y

{8.3.3.} Tyre size (by axle) : R18

{8.3.4.} Type approval number

(if available) : not available

(1.6.1.)Sound level of moving vehicle :

[8.1.]
{8.4.} METHOD A (Standard Silencing System)
measurement results rement results
2nd gear 3rd gear
left
rft 1) right
rioht left right
1) loe(n)'r
B(A) loaln;'r dB(A)
1st measurement 74.6 74.6
measurement 75.0 75.1
measurement 75.1 75.1
measurement 75.8 75.6
Test result 74.8 dB(A)/E 2)
{8.4.} METHOD A (Replacement Silencing System)
measurement results urement results

left right
1)
right
B(A)') loaln;1r loaln;,r
1st measurement 73.8 74.0
2nd measurement 74.3 74.4
3rd measurement 74.2 75.0
4th measurement 75.3 75.7
Test result 74.7 dB(A)/E 2)
1) The measurements values are given with the 1dB(A) deduction in accordance with provisions of item 5.2.2.5.1
(paragraph 6.2.2.1.)
ofAnnex l.
2) "E" indicates that the measurements in question were conducted in accordance with this Directive 7U157|EEC

TUV Rheinland ltalia S.r.l. Prrifl aboratori um / TE sr LABa pAroRy Seite I eaqe
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E24 59R-OOOOO3
PrUfbericht Nr.: 55 0323 09, Ausf. / Vers. 0
Test Report No:
ECE-R59
Hersteller/Manufacturer Milltek Sport Ltd.

Typlrype.
Derbyshire, DET 8DU, UK
VW GOLF GTi
A.
TUVRheinland

<6.3>r Measurement of Vehicle Performance - Exhaust Pressure

(Standard Silencing System )

Pressure, Vehicle Rpm

mBar
First Reading 17.4
Second Reading 19.4 5300
Third Readinq 17.4
Test result 19.4

<6.3>r Measurement of Vehicle Performance - Exhaust Pressure

(Replacement Silencing System )

Pressure, Vehicle Rpm

mBar
First Reading 17.2
Second Reading 18.9 5300
Third Readino 19.1
Test result 19.1

Limit Allowable increase 25%

Test Result -1.5%

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E24 SgR.OOOOO3
 A
PrUfbericht Nr.: 55 0323 09, Ausf. /vers.0
Test Repoft No.:
ECE-R59
H erstel ler/ M a n ufactu re r. Milltek Sport Ltd. hrSL fi1
Derbyshire, DE7 8DU, UK TUVRheinland
Typlrype: VW GOLF GTi

2.3. Additional information

The results of the test refer exclusively to the object(s) mentioned under point 1 .1 .

of this report.

Test site Millbrook Proving Grounds Limited, UK

Test date 30-07-2009

2.4. Remarks nla

3. List of Appendices Appendix 1 - Test Photographs

4. Statement of conformity

The above mentioned information document and the type described in that comply with the
requirements mentioned on page 1.

l-Ponte San Marco (BS), 2009.11.16

gb/fb

.sI
Vorgangsnummer: 8716568 E-Mail : francesco. barbierato@it.tuv. com
No. of practice Telefon : +39-030-965592 1
Telefax: +39-030-9655923

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E24 59R-000003
PrUfbericht Nr.: 55 0323 09, Ausf. / Vers. 0

A-
Test Report No.:
ECE-R59
Herstel ler/ M a n ufactu re r. Milltek Sport Ltd.
Derbyshire, DET 8DU, UK TUVRheinland
Typlrype. VW GOLF GTi

Test Photographs Appendix 1

1) Test Vehicle

2) OE Silencing System

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E24 59R-OOOOO3
PrUfbericht Nr.: 55 0323 09, Ausf. /vers.0
Test Repoft No.:
ECE-R59
Herstel I e r/ M a n ufactu re r. Milltek Sport Ltd.
Derbyshire, DE7 8DU, UK TUvRheinlaffd
Typlrype: VW GOLF GTi

3) Replacement Silencing System

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E24 sgR-OOOOO3
 INFORMATION FOLDER

Type : VW Golf GTi

No. 55503 23-09-00

Date of issue : 16-II-2009
Date of last change : not applicable

*** ** *** ** * * * * * * ** * * * * * * * * * * * ** * * * tr tr * * *

o Technical drawing with EC-Type identification no. 1 sheet

r General Exhaust Fitting lnstructions no. 2 sheets

E24 sgR-OOOOO3
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Milltek Sport

General Exhaust Fitting lnstructions

Before you start

. Check all the components against the packing list.

. For safety purposes and ease of installation, wherever possible take your vehicle to a qualified
installer with a vehicle lift.

. If carrying out a home-install, then park your vehicle on a level surface and allow time for the
vehicle and exhaust to cool down.

. Remember to always use axlestands / jackstands to support the vehicle when working under-
neath.

. Wear protective clothing, including eye shields.

. Disconnect the battery if working near electrical connections.

Removing the stock system

. Spray all bolts and joints and mounts with releasing fluid, allow to penetrate for about an hour.

. Release all connectors or clamps on the system and then start to dismantle the system from the
rear forwards. Some stock systems are installed in one piece by the car manufacturer before the
suspension or rear axle are installed, these systems will need to be cut to be removed.

. Stock systems are heavy, so make sure that you have help or can adequately support the system
when it is released.
. Sometimes removing the rubber hangers can be difficult, removing the bracket from the body
may be a better solution.

lnstalling the Milltek system

. Remove all protective packaging and assemble the unit on the ground, make sure that each joint
has a clamp and that the rubber hangers are transferred from the stock system, replace any worn
or damaged mounts.

. Smear a small amount of exhaust assembly paste inside each slotted joint, this will help prevent
leaks on start-up and prevent the pipes seizing together.

. Install the system, front to back without clamping any joints.

. Position the system so that the hangers are ideally inclined to the front of the car by 10 - 15mm,
these hangers will then move into their correct position when the system is hot and expands.

E24 sgR-OOOOO3
 MILLTEK SPORT
General Exhaust Fitting lnstructions

. Make sure that there is adequate clearance around the system, remembering that this system will
expand by around 25mm when hot.

. When the system is in the optimum position, tighten up the clamps from the front to the back,
adjusting the system as nece.ssary. Do not over tighten the clamps.

Running the Millteksystem for the first time

. Wipe off all oil, grease and fingerprints from your Milltek system.
. Make sure that all covers, heatshields and brackets have been replaced. '

. Reconnect the battery ifnecessary.

. Do not start the engine in an enclosed space, adequate ventilation is always required.

. Start the vehicle and allow to run at tickover until the system is warmed up.

. Check the system for leaks, it's not unusual for condensation to find it's way out of the joints in
the warm-up phase.

. Take your vehicle for a test drive, remember to bed the system in, don't use maximum accelera-
tion until the system has been for a short test drive and you have re-checked all the joints and
clearances.

E24 SgR.()OOOO3