PLZ HELP- 81 GLS manifold/downpipe.Issues with new ring seal

ok i heard they split where the two pipes join, but mine was actually blowing on the joint, so ive bought a new ring and clips from GSF…

I made a nice wedge (85mm i think), got the c clamps and down pipe off no probs.

ive cleaned up the manifold underside with sandpaper and a dremel, yet the ring is too small and doesnt fit onto the manifold :dontknow:  :dontknow:

the ring center messures 70mm at the bottom of the taper.

its ripping the wire as im trying to tap it on..

is the ring the wrong size? are there any other golfs which use a smaller size? whos done one of these.. got the MOT retest tommorow and this is all i got left to do.

cheers if anyone can help here.

Ok i know this sounds stupid but have you taken the old ring off? not meening to take the mick here

leggyvw said

ive cleaned up the manifold underside with sandpaper and a dremel,

yes ive taken it all off, and given the ring on the manifold a dam good cleaning, sanding, and even dremeling but its just not going on.

i dont wana lump hell out of the new ring incase its the wrong one.. are they meant to be 70mm ? are there any other sized ones.?

I've just measured a spare I have and its 72mm.

I don't know of any different sized ones but I know they are a tight fit on the manifold.

I just bought a genuine one and its a solid ring rather than the mashed together wire type! Maybe it will stop the squeek?

nice one ross your a star. Mines not a genuine VAG part, its from GSF, but it shouldnt be 2mm smaller.. ive damaged it a little (some of the wire is flaking off). Do you think i can dremel the inside out evenly to make it fit. or do i stand a chance of swapping it at GSF for another one. oh and out of intrest, how much is a new one from VW.

Just compared both types as I have both spare for some reason!!!

The wire type is maybe about 71mm and the solid one is about 72mm. I expect you have the right one and its just tight fitting. You just have to try your best to get it on without mangling it!

Cheers,

Ross

well ill have to remove a little bit on the inside of the ring or there'll be nothing left of it. im sure if i dremel out the inside a little bit, it will make a big difference in getting it on. It should still seal tidy as ive got new clamps and thier alot more tense than the old ones. the gap in the C is about 10mm smaller to the old ones when thier tight. ill let you know how i get on anyway. thx for the help  

I got it as a repair kit which included the 2 C clips too. It was ?18 +VAT My local dealer had them in stock.

Part number 161298115

If its blowing there you definately want to change the clips too. I cant see that there is a part number for just the ring on its own so I guess they think its false economy to just do the ring?

Not sure about GSF, you could try but I think they'll probably say no?

I think you should still be able to fit it if its not to far gone. I doubt it'll have to be absolutely perfect to seal well.

Good luck

nice one mate i just put the dremel over the inside to get some if the wire off (its way to thick). taken it back so it messures about 71 mm at the narrowest part so ill be having another go at putting it on tommorow. and in reffrence to what you said, i have got GSF clips here and they were ?1.50 each, and they seem thicker than the originals, plus they've been galv dipped so they should last. (lets just hope my homemade drift/spreader is up the the job..). ill update yo tommorow

ok after removing some of the inside of the ring, I managed to get it to fit over the manifold… I then cleaned up each end of the downpipe and got that connected with the C clips without any issues at all.. This got me quite excited, thinking it would all go together from here with no problems BUT… when i connect the middle section to the downpipe, i think its pushing the downpipe forawrd towards the driveshaft, and its causing it to blow again( at the ring)  :dontknow: .. and the rubber on mounting on the centerbox is lined up perfectly. theres no end to fitting these exhausts is there. anyway im outta ideas so if u have any let me know. i can get some pics up if needed.

Thats odd, never had or heard of that problem. Are you sure its the ring thats blowing, not a gasket between the manifold and head or something?? Is it loud, just under acceleration did the manifold perhaps have a broken centre divide? that makes a blowing kind of noise if missing…

http://www.vwgolfmk1.o…iewtopic&t=12331&start=10


What kind of condition are your engine mounts like? Especially the rear one? Maybe if they're worn and the engines dropped a bit then its more likely to blow?

Hey dude,

about to except the same mission on my rivage, think i have the same kit as you from gsf, 2 clips and wire gasket. Can you give me some advice on taking the old clips off and the technique on replacing them?

many thanks in advance!