Exhaust Manifold Leaking ??? Help

[daughtersbeetle]

My Daughter's Beetle has been sounding a bit loud, so we took it to the muffler shop. They said its either the Manifold or the gasket...

** Anyone have some advice on removing the Exhaust Manifold ??
** Wondering how hard this is going to be ?

I can get a used one from the junkyard and found the gaskets, so I just need some advice before I go jumping into this project.....

[Canadianbugin]

Originally Posted by daughtersbeetle

My Daughter's Beetle has been sounding a bit loud, so we took it to the muffler shop. They said its either the Manifold or the gasket...

** Anyone have some advice on removing the Exhaust Manifold ??
** Wondering how hard this is going to be ?

I can get a used one from the junkyard and found the gaskets, so I just need some advice before I go jumping into this project.....

I am presuming you have an AEG 2.0l...??? I have replaced my exhaust manifold,they seem to crack on the #4 cylinder for some reason..?? When i replaced mine i used all new hardware (studs,nuts,gaskets) Not really a hard job,just a little akward @ times.. Make sure before you start that you have the right manifold for your car... There are some with SAI(secondary air injection) and some without... I would also suggest you use OEM gaskets and hardware,as sometimes aftermarket stuff is sub-standard...GL..KP..

[Pseudotropheus]

You can find some used ones in junkyards, that are still in good shape for about 60-75 bux.

Otherwise, if your at all interested. You could always throw in a header and exhaust for the hell of it.
( I know it aint cheap, it's fun. Probably not logical ).

Is it a loud "ticking" sound?

[daughtersbeetle]

Canadianbuggin,
Yes its a 1998 2.0 -
Is there anything special I need to know about removing it or putting it back together ? The only thing in the way seems to be the heat sheild which I already had off for inspection.
It appears I can get to all the bolts from the bottom. I didnt know how much of a pain its going to be. Did you drop the exhaust at all or just remove the maifold

[daughtersbeetle]

Is it a loud "ticking" sound?

No it just sounds like the xhaust is getting loud, I had it at 2 muffler shops and they agree.
I will be buying a used one, cant justify 500+ for a new one...

[daughtersbeetle]

And it continues....
While looking at how to remove the exhaust manifold...found what I thought was a very small oil leak from the oil plug, upon a closer look the oil pan has a hairline crack on the bottom just in front of the plug.
I will be ordering a steel bottom pan, and while Im at it do another transmission filter and gasket, fluid since its right there.

[simonsi]

Originally Posted by daughtersbeetle

Is it a loud "ticking" sound?

No it just sounds like the xhaust is getting loud, I had it at 2 muffler shops and they agree.
I will be buying a used one, cant justify 500+ for a new one...

Manifold or gasket leaks at the manifold do usually give that loud ticking sound referred to, if you don't have that then I'd doubt you have a manifold problem unless you have some other indicator.

[Pseudotropheus]

You may have a leak somewhere, but if your not getting a loud "ticking" sound, I would look elsewhere, then exhaust manifold gasket.

That is the most common noise you will hear in that case.

[daughtersbeetle]

Im going to take it apart in the next week or so. Worst case I have a cracked manifold, if we dont find any cracks new gaskets and sealant should be the ticket....

[Canadianbugin]

Originally Posted by daughtersbeetle

Canadianbuggin,
Yes its a 1998 2.0 -
Is there anything special I need to know about removing it or putting it back together ? The only thing in the way seems to be the heat sheild which I already had off for inspection.
It appears I can get to all the bolts from the bottom. I didnt know how much of a pain its going to be. Did you drop the exhaust at all or just remove the maifold

Use new hardware...Nothing special you need to know.... Yes i dropped the centre mount,helps with space... When you remove the manifold,have a very close look @ cylinder 4's pipe that should be the one that is cracked if any...(furthest away from your timing belt)..GL...KP..

[gamefoo21]

Originally Posted by Canadianbugin

Use new hardware...Nothing special you need to know.... Yes i dropped the centre mount,helps with space... When you remove the manifold,have a very close look @ cylinder 4's pipe that should be the one that is cracked if any...(furthest away from your timing belt)..GL...KP..

Just to add, use Nickle Anti-Seize on the bolts.

The nuts on the manifold to downpipe flange are M10 x 1.5

Also, I would suggest replacing the exhaust manifold flange gasket.

[daughtersbeetle]

Getting ready to work on the bug this weekend.

*How did you remove the studs ??

I have new gaskets and nuts,thread locker etc...didnt think about replacing the studs.....

[daughtersbeetle]

This is what I have lined up for repairs...

1) Exhaust Manifold - New gaskets,harware etc..
2) New Oil pan with steel bottom
3) Oil Cooler O Ring - since I will be changing the oil pan,oil filter etc
4) Transmission filter,fluid etc- Ive done this before, fairly easy
5) Repairing a vacuum leak correctly- I just put tape over till now....
6) Front Rotors - Already replaced the pads two weeks ago...might have caliper issue...find out when I get in there..
7) Clean the motor with engine bright...so I can keep an eye out for any leaks...

I think thats enough for one day.


Im praying this will keep the Bug going for a while with no other issues.....geez...

Later this year I will replace the oil cooler o-ring for prevenative maintanence

[Canadianbugin]

Originally Posted by daughtersbeetle

Getting ready to work on the bug this weekend.

*How did you remove the studs ??

I have new gaskets and nuts,thread locker etc...didnt think about replacing the studs.....

I have a stud extractor,but you can use vise grips and if you need heat,a torch.. Wise to replace all the studs and gaskets. Also what i did,was to soak all the hardware you are removing with penetrant...

[daughtersbeetle]

Alright heres the list and this is what was completed...

1)(Never got to it) Exhaust Manifold - New gaskets,harware etc..
2)(Broke a bolt,but got it out,done) New Oil pan with steel bottom
3)(Done) Oil Cooler O Ring - since I will be changing the oil pan,oil filter etc
4)(Done) Transmission filter,fluid etc- Ive done this before, fairly easy
5) (broke the tubing..great)Repairing a vacuum leak correctly- I just put tape over till now....
Air Injection hose
6) (Didnt have time)Front Rotors - Already replaced the pads two weeks ago...might have caliper issue...find out when I get in there..
7)(Done) Clean the motor with engine bright...so I can keep an eye out for any leaks...
8) (done) Aim Headlights
9)(Done) this is why I still have to do a couple more repairs....
While under the car, below the drivers door on the bottom of the car there are round rubber grommetts(WHY), one had fallen out so, the hole had become enlarged(great)....Repaired it with some sheet metal,3 sticks of JB weld,under body rubber spray...

No more oil leaks......

[Canadianbugin]

Good job.... Now on to the exhaust manifold...

[daughtersbeetle]

Looks like we will give it another go on Saturday......

[Canadianbugin]

Originally Posted by daughtersbeetle

Looks like we will give it another go on Saturday......

Let us know what you find.... Curious to know if it is cracked in the same spot as mine was.....GL...KP...

[daughtersbeetle]

I will let you know.....

[Canadianbugin]

Originally Posted by daughtersbeetle

I will let you know.....

Thank's... Good luck..