Exhaust manifold

[CaiosG60 PWR 0]

I've got a blowing exhaust manifold. Got a replacement and all the gaskets, etc. But I've tryed to fit it and I carn't do it. I'm not hugely mechanical! :lol: I tryed to take the injection manifold off but carnt get good access to the bolts on the back of it. Is there a trick to this?

 

 

P.S. Its a Golf G60 but its the same manifold and I reckon the access is about the same.

[andycowuk 0]

4 elbows, 5 wrists and variable length fingers.

 

As far a i can remember, there are five, I got them out using a small socket (1/8 drive), the bolts should not be that tight. there is nothing enjoyable about the job.

 

When I was taking my exhaust manifold of 3 weeks ago, some of the studs snapped. This is apparently quite common. Now I am waiting to get my de-studded head back............

[steveo29 0]

its a slag mate...unless your very handy/lucky your prob gona have to take the head off/drop the engine....its tricky to take the manifold off with it on the bench

 

consider paying a decent garage...they will heat the nuts and possibly save snapping em

[Henny 0]

Yup, I can also agree that this is NOT an easy or pleasant job... :( I've done one on a MKII 8V GTI before (basically the same as a G60 golf) and it's still not easy... I'd say you're best off taking it to a good local garage and just bend over and be prepared to take it... :shock: :?

[Brando 0]

Does this go for 2.0l 16vs as well??

 

I have a small crack in mine and am currently thinking of doing it myself????

[Henny 0]

Never had a play with one of those, but, based on 1.8 16Vs, they are easier to do than the 8Vs 'cos the inlet manifold isn't in the way of the exhaust manifold. As with all exhaust manifolds, beware of snapping studs off as they do tend to go brittle with age... :shock: :?

 

You're probably best to split the inlet manifold so that there's nothing on top of the head to impede your access to the exhaust manifold, it's only a few more nuts and one new gasket required, but it means that all of the pipework and throttle linkage etc won't get in the way of what you're doing...

 

Anyone got any better ideas on this, as, like I say, I've not done one on a 2.0 16V before... 8)

[davidwort 0]

do you mean downpipe rather than manifold? never heard of a cracked manifold as they are cast iron!

The downpipe is a ba-lamb, best to do with the car up on a garage ramp as you need like 3ft of clearance to get it in/out over the sub frame - and then it's blinkin tight.

 

David.

 

Does this go for 2.0l 16vs as well??

 

I have a small crack in mine and am currently thinking of doing it myself????

[Brando 0]

Not sure tbh m8, how would I check. I put my car in for a service and the told me I had a cracked exhaust manifold but it wasn't anything serious yet. They just wanted me to be aware of it.

[Henny 0]

Cast Iron manifolds do crack occasionally.... I'll admit it's not particularly common on VWs, but it wouldn't suprise me if it has cracked as diagnosed.... :?

I've known of a cast iron engine block that cracked due to some prat putting cold water in when the engine was hot... :shock: :roll: Consider that the exhaust manifold is pretty much the hottest part of a non-turbo car with the least cooling... Any slight flaw in the casting is gonna get stressed every time you fire up the engine, add in the weather and possible engine washing when hot by a previous owner/garage, and it's pretty good that they tend to last as long as they do! :shock: :lol:

 

It could be worse... My mate had a Merc and the manifold on that cracked... He was quoted £1500 for a new one + fitting by Merc, £800 + fitting by a second hand merc place that would only give 3 months warantee and £950 for a custom made one + fitting... Oh, and fitting was between 5 and 8 hours labour! :shock: Not good on a £3K merc! :shock:

 

He sold it in the end! :lol:

 

If you're not sure if it's the donwpipe or manifold, take it to a GOOD exhaust specialist and ask them to show you where it's cracked as they do a quote for you... Shouldn't cost you anything and you don't have to take them up on the quote... :wink: 8)

 

p.s. Brando I luuurrrvvveee your end quote! Sums me up to a tee! :lol: :lol: :lol:

Stupidity got me into this mess, so it can damn well get me out!

[h100vw 0]

I welded up a crack manifold on my mates Uno turbo years ago. I ground the crack nice and deep with my angle grinder.

I wound my mig up to 'ludicrous Amps'. Then ran a big bead down each side of the crack. The heat closed the gap and then I filled in the rest. It lasted over 2 years and was chuffing again when he sold it.

 

Gavin

[Banana Man 0]

I have also done the job took me 3 attempts but got there in the end I did it without taking the inlet manifold off or the exhaust manifold by taking it through the hole between the steering rack and chassis tunnel. ( If you dont have acces to a 4 poster ramp dont try taking it through from the bottom though as it's impossible) TThe inlet manifold should come off quite easy as the bolts shouldn't be done up really tight just a bit of gentle persuasion but it is in a really awkward position 9 I know coz I took the inlet and exhaust manifolds off 2 weeeks ago) took me about 3 hours to get them off and the back of my legs caned afterwards from leaning over the engine. I would expect that the flexi joint is probably where it is blowing from especially if your exhaust moves about a bit!

 

Good luck it is a bas*ard of a job!!!

[dubbprince 0]

i think the cast iron ones have to be brass rod welded...any other welds don't hold long enough i've been told.

I had a crack in my mk4 polo manifold, it cost £50 for one delivered 2nd hand.