Exhaust Manifold gasket replacement

Ok I have a slight leak from what seems to be the Exhaust Manifold gasket (although it's hard to tell).
Mines the 1.8 with the Digifant fuel system.

Now I was at the VW Dealer yesterday for a qoute on an Insurance claim and asked what would in cost.
Well first of all he told me that it is most likely the Manifold itself has warped out of shape and I would need a new one. No idea why he should even think that as he hadn't even seen the car let alone the problem.
That's a bit like telling him your car won't start to which he replies, "well you need a new engine"!  

So anyhow, I asked what it would cost to just replace the gasket?
He replied (after checking) and said around 300 GBP + parts or 350 Euros +…

Now is this something that I can do with limited knowledge and limited tools?
How hard can it be?
Do I need a ramp?

I don't have my own garage or workshop and it's been a very long time since I did anything like this.

Also can someone point me to the correct Part Number for the gasket itself please?
Should add that the engine and exhaust are completely bog standard.

Appreciate any advice Guys!  

Here's your gaskets - http://www.ebay.co.uk/ctm/Exhaust-Manifold-Gasket-VW-Golf-1-


Manifold is held on with 8x10mm nuts, you'll want a 1/4" drive with a couple of long/wobbly extensions and a lot of patience.

 It's doable from above but MILES easier from underneath…and…its doable with the inlet in place but its MILES easier with it removed.

half a saturday, 2 or 3 cuppas and 6 or 7 fags..

I like it in tea and fag terms

big_nick said

Here's your gaskets - http://www.ebay.co.uk/ctm/Exhaust-Manifold-Gasket-VW-Golf-1-


Manifold is held on with 8x10mm nuts, you'll want a 1/4" drive with a couple of long/wobbly extensions and a lot of patience.

 It's doable from above but MILES easier from underneath…and…its doable with the inlet in place but its MILES easier with it removed.

half a saturday, 2 or 3 cuppas and 6 or 7 fags..

Cheers for that!  
I do like the Tea and Fags timing as well.  

If you get a bit of hose pipe and but one end to your ear and move the other end around the manifold and exhaust down pipe you can pin point the exhaust leak just incase its a different gasket or the down pipe that is leaking.
I've changed my exhaust manifold gaskets on a DX Kjet engine with the inlet in place, I did it from below with the car on jacks and axel stands, there is not alot of room behind the engine and you have to work with your arms in the air trying not rust/dirt and tools in your face, safety glasses are a good idea! New brass nuts will also be needed as well as the gaskets.

mark1gls said

If you get a bit of hose pipe and but one end to your ear and move the other end around the manifold and exhaust down pipe you can pin point the exhaust leak just incase its a different gasket or the down pipe that is leaking.
I've changed my exhaust manifold gaskets on a DX Kjet engine with the inlet in place, I did it from below with the car on jacks and axel stands, there is not alot of room behind the engine and you have to work with your arms in the air trying not rust/dirt and tools in your face, safety glasses are a good idea! New brass nuts will also be needed as well as the gaskets.

Hey thanks Mark for that, I'll do that.  
 
I must admit glasses and new Nuts at my age (no) I mean the cars age is a very good idea indeed.  
 
Andy 'smudger' now if you pick up on this thread just don't go there ok!    
Please not after the Flaps episode…  

Mark, because I live in Vienna where parts are very hard to find (it's a bit like tracking down 'Lord Lucan') do you know a supplier for new Brass Nuts by chance?

brass nuts?

  http://www.ebay.co.uk/itm/M8-BRASS-FULL-NUTS-8mm-NUTS-10-PACK-/130898970714?pt=UK_DIY_Material_Nails_Fixing_MJ&hash=item1e7a2fc85a

  

You might find when removing the old nuts from the exhaust manifold they are a little rounded off so you might need to hammer on a slightly smaller socket, put the socket on an extention bar then hammer it on.
Also on mine a couple of studs unscrewed when removing the manifold, if this happens lock 2 nuts together one end of the stud when its removed then undo the old brass nut.
Pics of mine, you can see the studs which came undone.

Has that manifold been changed at some point? I thought that all GTI's had the 6 bolt type manifold and only big block carb motors had the toilet bowl?  
 or is it a caddy-specific thing?

early gti have the toilet bowl, not sure if the later ones had the 6 bolt flange, might be cab and rocco only? not 100% on the mk1 but yes its possible they could have either

rubjonny said

early gti have the toilet bowl, not sure if the later ones had the 6 bolt flange, might be cab and rocco only? not 100% on the mk1 but yes its possible they could have either

Ok time to throw the curve ball!

Although mines not a 'GTI' I have the 98bhp motor with the 'Digifant Fuel Injection System'.
Does that make a difference anyone?  

big_nick said

brass nuts?

  http://www.ebay.co.uk/itm/M8-BRASS-FULL-NUTS-8mm-NUTS-10-PACK-/130898970714?pt=UK_DIY_Material_Nails_Fixing_MJ&hash=item1e7a2fc85a

  

Cheers for this and all your other really helpful advice Mate.
I do appreciate it!  

makes no odds what manifold n downpiep it has on it, the gaskets/nuts etc is all the same. though if it was me I would have a shufti and if its got the toilet bowl take the opportunity to get a 6 bolt flange type one as it flows a bit better

main thing is make sure the downpipe is proper gti one with a kink so it clears the roll bar, IO have seen them without in the past which is fine if you dont have a roll bar but yours should have one I expect (if not fit one of those as well!)

Ok time to throw the curve ball!

Although mines not a 'GTI' I have the 98bhp motor with the 'Digifant Fuel Injection System'.
Does that make a difference anyone?  


You have a DX on Digi?!  I thought it was limited to PB, PF and RV motors…is it definitely a DX?  Digifant or Digijet?   I could have sworn that all A1 cars were carb or Kjet…unless its been modded or swapped in the past?

 But no, it wont make a difference - the gaskets are the same on pre mk4 stuff

the very late cabs got digifant II, the engine code is 2H on those ones

rubjonny said

makes no odds what manifold n downpiep it has on it, the gaskets/nuts etc is all the same. though if it was me I would have a shufti and if its got the toilet bowl take the opportunity to get a 6 bolt flange type one as it flows a bit better

main thing is make sure the downpipe is proper gti one with a kink so it clears the roll bar, IO have seen them without in the past which is fine if you dont have a roll bar but yours should have one I expect (if not fit one of those as well!)

 

Can you help Mr. Thicky here for a moment because I'm not sure I follow you John.
Any chance of a picture or two to help explain what you mean by all that as my head is still spinning with the 'toilet bowl' idea!  

I'm not concerned about getting a bit more out of the engine, in fact I'm working really hard to keep the car bog standard spending a fair few quid in the process.
I don't have easy access to a pillar lift so that I can have a good look round. I have to rent one, so I was hoping to get all the parts I need and do the job one time and not twice. If you see what I mean.  

ah well then, just forget we ever mentioned it and carry on with the job

basically the 'toilet bowl' is the style as pictured above, which is a 4->1 type exhaust as all 4 exhaust ports are squeezed into 1 at the downpipe junction.

on the '6 bolt flange' type its a 4 -> 2 -> 1 system as the 4 ports join down into 2 pipes at the manifold, then finally join into 1 near the bottom of the downpipe.

toilet bowl:


6 bolt flange:


edit: well technically I suppose you could call the toilet bowl a 4 -> 1 -> 2 -> 1 as it splits again after the join, either way its more restrictive

big_nick said

Ok time to throw the curve ball!

Although mines not a 'GTI' I have the 98bhp motor with the 'Digifant Fuel Injection System'.
Does that make a difference anyone?  


You have a DX on Digi?!  I thought it was limited to PB, PF and RV motors…is it definitely a DX?  Digifant or Digijet?   I could have sworn that all A1 cars were carb or Kjet…unless its been modded or swapped in the past?

 But no, it wont make a difference - the gaskets are the same on pre mk4 stuff

God I wished I knew what everyone was talking about, it's like learning a new Language!  

Here's the only Pic I've got with me at the moment, so what is it?



 

its a 2H
basically DX engien, with digifant II management off a mk2 golf plus CAT

rubjonny said

its a 2H
basically DX engien, with digifant II management off a mk2 golf plus CAT

Ok John, just saw your pictures and now that does make sense.

Q. on the Digifant II. I'd read somewhere that version was only available in the US (California) I believe or is that just twoddle?