HELP !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

My accerator cable has worn a large slot in the alloy inlet manifold, about 2" x half an inch, from rubbing against the casting,I can hear hissing coming out of the slot. If I put my finger over the slot the engine revs, if I pull out the cable from the slot the engine cuts out. Alloy particles have also clogged up the butterflies in the throtle housing.

I need a new inlet manifold, is the 1600 and 1800 the same? Wil a mk2 inlet manifold fit my 1800 mk1?

As a tempory fix you should clean the area of damage and fill with either Araldite or similar. The throttle butterflies should be cleaned once the throttle is removed using carb cleaner.
Looking at ETKA it would appear that the same part no, 067 133 201 L has been used on the MK1 Golf from 1975.

Simon

Thanks SIMAC,

Do you think car filler will do the trick?

Its amazing how the casing from the accerator cable can do so much damage. The plastic melted away which exposed the steel casing around the cable, this acted like a file. I suggest everyone check that the cable is well away from the inlet manifold!

I don't know if the car filler will take the heat. There are various metal type putties out there that would be ideal.

Simon

as simac said the 1600 and 1800 are the same, the mk2 inlet manifold wont fit as the throttle body is on the left rather than the right as a mk1...JB weld would be good as a temp fix and will only cost about a fiver.

I took off a 1600 GTI inlet manifold from the local scrap yard today, the numbers where slightly different, the 1600 manifold number ended in 7f and my manifold ended in 5f. Anyway after a struggle with the allen key bolts, I managed to get the 1600 manifold on and the engine is now running although with a lot more poke!!!

I was annoyed to find that my old manifold only had 2 allen key bolts holding it on. I had the head refurbished a year ago. Guess you just can't trust anyone to do a good job.

It was the clutch cable that did the damage to the manifold, the hole was huge on closer inspection! If you want to avoid a big problem, make sure your clutch cable is not touching the inlet manifold.

Last point, thanks chaps for the quick replies. Off to open up 4 cans of red strip.

Cheers