EXHAUST MANIFOLD

Going great guns on my 1.8 GTI Resto . Then i removed the down pipe to replace it with an Ernst item and sheared 2 bolts flush in the manifold . Its a six bolt fixing type . Has any body bought a new manifold for the GTI recently ? Any one got a "Very good one for sale" ?

This is the worst job i have done on the car , took 3 hours to remove it all so i want to put it back once only this time . If you can help please drop a reply cheers Chudd….

i have a standard manifold you can take off my hands one stud is missing but easily replaced its a bit rusty as most are i think its been in my shed for ages you can have it if you i'll email you some pics if you want a closer look.

Crazy

cheers for that where are you as a matter of interest ? I am thinking postage costs , will all the studs come out do you think as i want to remove and replace the lot new from scratch so i never have to do it again cheers Mate Chudd..

I had the same problem when I renewed my front down pipe. The two middle studs snapped off on the manifold, however I decided to renew all six studs. Just heat up the studs and use a very good quality mole grips and undo. The studs are still available from the main dealer.

Chudd - Standard manifolds have a different bolt pattern for the down pipe than the GTI.

…and of course with the GTI, the manifold studs are one the back of the engine!!

I snapped one when I was changing my 1272cc for a Polo GT motor.  The reason they snap is that the studs are not of the same metal as the cylinder heads (light alloy) so they craze in and bond themselves into the head.  Same as annoying Saxo brake pins for anyone who has done them before…

Anyway, on mine, one the manifold was out of the way there was a small amount of stud sticking out of the head.  I hammered an old socket on and turned it out with a breaker bar.

If it shears flush with the head you need to drill it out and send a helicoil down the hole.  Alternatively you can get stud extracters specifically for getting snapped studs out - these are available from Machine Mart for not a great deal of money.

Basically you drill a small polit hole in the stud and turn one of these thigns in - they are like self tappers with a reverse thread and you turn them in the "loosen" direction.  Theroy goes that when the are in as far as they can be, they will bite and the turning force you continue to apply is in the right dirrection to now loosen the threads the stud is bonded into.

make sure you get good quality stud extractors or they will just brak off making it near impossible to drill out the stud!

have pm you chudd