Inlet manifold removal??

In the quest for smother running I have decided to replace the inlet manifold gasket.  New injector seals made a big difference so am hopeing this will too.

Question is…..do I need to remove the exhaust manifold shroud before removing the inlet manifold or will the manifold come straight off??

Just trying to get an idea of the amount of effort/time required to do this.

Cheers

Dein

assumig you have a 8v gti like me,

the inlet manifold is independent from the exhaust manifold.

it is a tricky job though, you need alan key sockets (think its a 6mm) and alot of patience because its very tight round there.

there 4 short bolts and two longer bolts

yep, its an 8v gti.  

There seems to be a heat shroud just under the inlet manifold.  I was just checking to see if I can remove the inlet manifold without removing the heat shroud.   Have you done this brindle?

Thanks again

Just poped out and had a go now.  The middle four were quite loose (prob not a good sign) and came off quite easy.  

Will tackle the outside two on sat when I get a replacement gasket.

a gasket is ?2.53 from GSF with the members discount….just so you know.

its dead easy to do… you need to disconnect the wiring to the AAV, undo the 5th injector from the head (you should really fit a new gasket to this too) undo the inlet pipe where it attached to the throttle body and undo the metal pipe bellow the boot just before the throttle body..then undo the breather and vac pipes where they attach to the inlet manifold on the front and undo the pipe from the AAV that comes round the front of manifold..also remove the throttle cable from the throttle body.

now undo the bolts with the 6mm Allen key and lift the inlet manifold and throttle body out as one.

remove the old gasket and clean up the mounting faces, both on the manifold and on the head… making sure no bits of old gasket go into the ports!!! very important!

both faces need to be spotless! brake cleaner is good with a rag to remove most stuff, and on the manifold face a bit of wet and dry on a sanding block with give a fresh face but be careful as its only aluminium and its cast so its very soft.

when rebuilding you have 3 options…

build dry and use the gasket as it is….

use a fine smear of normal high temp grease on the gasket to give it a little stick and to help fill any imperfection and keep the gasket supple.

or use some Loctite 5926 Blue gasket sealant / Hylomar universal blue sealant - put a smear of each of these on each side of the gasket and clamp up, but only a smear! otherwise it may end up being squeezed into the the inlet ports!! this is the most permanent fix, but is also more of a pita of you have to remove the inlet manifold at a later date  :wink:

hope this helps. I will also be doing this as part of a guide this weekend…but it prob wont be up till next week which i guess wont be much help to you

Karl.

lucky bugger, no heay shroud on mine. wish there was!

its all simple enough dude!

Just remember where everything goes

Let us know how you get on

Peace

Cheers for the tips.  Its all good to think twice and act once.  The manifold is off and there were no surprises.

However, the manifold ports have loads of crud in them! Looks like oil gunk from the breather system.  I did clean out the valve cover oil condenser thing last summer so this may be from that.

Question is….will this affect running.  Is there a way or any point in cleaning the ports??

Cheers again

Deiniol

All done!  Fitted the new gasket and started her up and she was running a bit higher on tickover.  Good sign…the last gasket seems to have been leaking.  

I adjusted the mixture with colour tune and found that a little more fuel made her run better.  Does this sound right????

All in all best ?2.50 I've ever spent.  She's running smoother on idle, much smother stopping and starting round town and most importantly while gunning down the duel carriageway.  She also seems to have more power.  Scotty would be proud.

I've been running mk1 golfs for about five years now and changing the injector seals (?2.00) and inlet manifold gasket (?2.50) has got to be the best value for money job to improve overall running I've done.  

If you haven't done these two fairly easy jobs on your car then do it and improve the performance and fuel efficiency of your gti.

cheers for the tips by the way.  Made the job much easier with a bit of foreknowledge…

thats what im here for  8)  Im glad I have been of some help.