Exhaust Manifold Leaking ??? Help

[daughtersbeetle]

Air injector hose replaced, cross that off the list...60.14

getting closer to the manifold and front rotors(caliper?),tire rotation

[daughtersbeetle]

Hey Canandianbuggin....

Exhaust Manifold
Did you remove it all from the bottom or did you remove the intake manifold and heatsheild from up top ...If im going to remove the intake I will do a valve cover gasket while at it, It looks like it could use one

[daughtersbeetle]

Well Ive just about had enough of this car.....Been working on it all day again..trying to get the ""Easy to remove"" intake manifold off, what a mess...I removed the 5 bolts up front, the back to are almost impossible to get to. I would like to meet the engineer and kick him in the balls...
After 7 hours, I have one of the rear bolts out and strip on the other,looks like it may just be going together and going up for sale, buy an american car....

[daughtersbeetle]

Hey Canadienbuggin......
How did you get the bottom 2 bolts towards 3/4 cyl ??
I soaked all the bolts with "Nut Buster" they are comming out ok....

Also got that stripped bolt out of the back of the heat sheild with a bolt extractor.
Will do a valve cover gasket,throttle body gasket/cleaning too since its off, replace a hose (hard 1/4"),....

[daughtersbeetle]

I dont have it off yet, but the manifold looks ok, maybe just old gaskets.

[daughtersbeetle]

This is going to be a slow go.....
I have removed 7 of the 8 bolts...the last one I cant get anything on it.
Socket - cant get enough swing
wrench - nope
offset boxend - maybe,but the amount of swing is an issue..

The bolts for the downpipe are very rusty 2 out and the bracket bolt,still have 4 more and one is going to be a pain,might ahve to use a bolt remover on it...

to be continued Monday.....................

[daughtersbeetle]

Update;

I removed the stripped out manifold bolt with a bolt extractor.
After a lot of work, the exhaust manifold was removed and inspected, looks perfect ? Put new gaskets,bolts etc and put it back together.
Still sounds the same, so now Im thinking about replacing the downpipe with cat....someone welded around the spring looking thing.
Anything I need to remove to get this out and install a new one ?

[Canadianbugin]

Originally Posted by daughtersbeetle

Update;

I removed the stripped out manifold bolt with a bolt extractor.
After a lot of work, the exhaust manifold was removed and inspected, looks perfect ? Put new gaskets,bolts etc and put it back together.
Still sounds the same, so now Im thinking about replacing the downpipe with cat....someone welded around the spring looking thing.
Anything I need to remove to get this out and install a new one ?

Sorry you found this repair to be a pain... I've worked on German cars since i was a kid... Comes naturally... If what you are talking about is the flex part of the downpipe? If this has been welded before it must be ready for replacement. I replaced it all in one shot(downpipe w cat and manifold)When you had the manifold off did you have a really close look @ the connections ??? As that's where the manifolds usually crack...(where the pipe goes into the collectors) If your going to remove the downpipe with the cat it is easiest to drop the "wing mount" or the center mount,undo the clamp and slide the downpipe out.FYI this downpipe is not cheap... I paid 280cad.But i have connections for parts here.. Question... Did you remove the manifold from the bottom..?? I did most of the removal from under the car...(had it on ramps @ the front and stands @ the back) The only thing i removed partially from the top was the Kombi valve heat shield(the one which has the valve in it)(Kombi valve)SAI hose connects to that...And back of the intake manifold. Let me know if you have any other questions...Jim...

[daughtersbeetle]

Thanks for your help Jim.
It was a pain, because I was lazy and tried not to remove a couple things at first and stripped the last nut for the intake manifold on the heat sheild.
After i removed the cowl and everything else,it went fairly smooth.
Yes I looked at it very close, and it appears in very good shape. The downpipe had been welded around the "Spring Looking" part of the pipe near the top, so Im going to replace it all the way back.
The Downpipe with cat(Stainless Steel) is 229.00
The muffler section is 134.00, so worst case 363.00 plus clamps etc 400.00

I removed the manifold from the top, after all the bolts were out, used a whole can of nutbuster.

You say to remove the center brace for the exhaust ?

[Canadianbugin]

Originally Posted by daughtersbeetle

Thanks for your help Jim.
It was a pain, because I was lazy and tried not to remove a couple things at first and stripped the last nut for the intake manifold on the heat sheild.
After i removed the cowl and everything else,it went fairly smooth.
Yes I looked at it very close, and it appears in very good shape. The downpipe had been welded around the "Spring Looking" part of the pipe near the top, so Im going to replace it all the way back.
The Downpipe with cat(Stainless Steel) is 229.00
The muffler section is 134.00, so worst case 363.00 plus clamps etc 400.00

I removed the manifold from the top, after all the bolts were out, used a whole can of nutbuster.

You say to remove the center brace for the exhaust ?

Yes i dropped the centre mount. Easier to line-up the downpipe this way as mine is one piece...(Cat and downpipe)... Your wellcome anytime...

[daughtersbeetle]

Canadianbugging ?
Im going to look under the bug Saturday, but the pics show another muffler ?
Is there three sections to the exhaust ?
I thought just the downpipe with cat - rear muffler section , is there another muffler between the two ?

[Canadianbugin]

Originally Posted by daughtersbeetle

Canadianbugging ?
Im going to look under the bug Saturday, but the pics show another muffler ?
Is there three sections to the exhaust ?
I thought just the downpipe with cat - rear muffler section , is there another muffler between the two ?

The stock exhaust has...From front to back....Cat,Resonator,Suitcase muffler,Tailpipe muffler.... So -exhaust manifold,downpipe w\Cat,center pipe with resonator & suitcase muffler,tailpipe w\muffler... Most loose the suitcase muffler because of cost....

[daughtersbeetle]

Just check out the system, heres what i have going on.

1) downpipe w/cat
2) front muffler
3) rear clam muffler

Now heres my question - Someone has welded the 2nd to the 3rd with no clamps. If I order the Downpipe and rear muffler, can I order a pipe for the center or do i have to replace that as well ?

http://www.racepages.com/includes/se...NvbXBvbmVudHM=

[Canadianbugin]

Originally Posted by daughtersbeetle

Just check out the system, heres what i have going on.

1) downpipe w/cat
2) front muffler
3) rear clam muffler

Now heres my question - Someone has welded the 2nd to the 3rd with no clamps. If I order the Downpipe and rear muffler, can I order a pipe for the center or do i have to replace that as well ?

Race Pages

Not sure what you're asking....If the two pieces are welded can you not separate them by cutting them..??? I assume the center section is o.k....??? What i would do in this case is order the down pipe... Test fit it when you get it and then you'll know where to cut the centre section...? In factory fitment this section has a VW sleave clamp...

[Canadianbugin]

Any progress OP...????

[daughtersbeetle]

I ordered the full exhaust...
Just received the front,rear mufflers and clamps. The downpipe cat and hangers will be here next week.
Im going to replace the front ABS sensors, a couple vacuum lines and heater control unit at the same time.

[Canadianbugin]

Originally Posted by daughtersbeetle

I ordered the full exhaust...
Just received the front,rear mufflers and clamps. The downpipe cat and hangers will be here next week.
Im going to replace the front ABS sensors, a couple vacuum lines and heater control unit at the same time.

Good luck as it sound's like you're having a tough time....

[daughtersbeetle]

i will let you know. Looks like i will start on Friday

[Canadianbugin]

Originally Posted by daughtersbeetle

i will let you know. Looks like i will start on Friday

Good luck.....

[daughtersbeetle]

cant get the rear muffler in.
wont go over the rear end