Exhaust Manifold studs and nuts replacement?

Looking at replacing my exhaust system, and the studs and the nuts holding the manifold onto the head look pretty badly corroded.

I also suspect the 6 nuts and studs on the join between the manifold and downpipe are not in a pretty state.

If possible I'd like to replace both sets of studs and all the related nuts.

Firstly any tips on removal (especially studs), and secondly anyone know the correct part number for the studs and nuts for a late '83 Campaign with the 6 stud downpipe join?

I was wondering if it would be possible to use more durable studs and nuts - say stainless steel? Anyone looked into this?

Also any VW part numbers for the correct studs and nuts would be good. ETKA is not crystal clear on the studs especially.

Cheers,

Chris

You will most likely find that the studs in the head will come out when you undo the nuts that hold the manifold on, i have a bag of them here so will check the part number for you when i get a chance, the studs in the manifold do have a tendancy to snap so give them a good wire brush and soak in wd40 before trying to undo the nuts which hold the downpipe on, the studs are not the easist to remove and will need soaking in wd40 and some heat as they are often rusted into the manifold, i used stainless nuts when i put mine back together which should make it easier if i ever need to remove it again

Okay the part number for the studs in the head is N 044 411 5  your etka wont find it using search as afaik only vw can search for n numbers, you will need 8 of these but im sure you already know that  

Thanks Storm - better add that to my list of parts to order tomorrow  

Chris

Chris

For the studs in the manifold I used N01444312. I also used copper nuts 059129601.

Cheers
Rajan

Thanks Rajan.

I know they are going to be a pig to remove, but once done hopefully if reassembled with stainless or plenty of copper grease they shouldn't sieze in future  :?

Chris

Exhaust Gasket 4 pieces : 028 129 589
Studs x8 for the cylinder head to manifold: 044 411 5
Nuts brass x8 for above studs : 900 850 01
Studs x6 10mm for down pipe to manifold: 044 520 3
Nuts x6 for above studs for down pipe : 102 090 05

OK, with MOT looming I have finally got back onto this again :roll:.

Chudd, can I just check if any of those part numbers you have listed there should have an "N" in front of them (guessing the cylinder head to manifold ones are the same ones Storm81 was mentioning?).

Also I notice that the studs and nuts you used were different part numbers Rajan - were yours for a late model 1.8 GTi?

Apologies if it seems like I am being picky, but when I ring up my dealer I need to know exctly the right part numbers otherwise I get the ole "nah, we don't have that on our system" excuse  :roll: .

Also if anyone happens to know the part numbers from ECP or GSF for same parts I'd appreciate it. I don't want to pay over the odds if I can get the same stuff much cheaper from GSF / ECP  :wink: .

So to summarise I need to confirm the VW / ECP / GSF part numbers for:

* exhaust manifold to downpipe gasket (x1)
   VW:  ??????          [cost ea. ?]
   GSF: 28214          [?1.64 ea.]
   ECP: ??????          [cost ea.?]

* inlet manifold to head gasket (x1)
   VW:  ??????          [cost ea. ?]
   GSF: 11810          [?2.70 ea.]
   ECP: 373440020   [?2.42 ea.]

* exhaust man to head gasket (x4)
   VW: V 028 129 589 [?2.02 ea]
   GSF: ???????        [cost ea. ?]
   ECP: 373440060   [?0.99 ea.]

* cylinder head to manifold studs [8mm] (x8 )
   VW:  N 044 411 5 [?0.57 ea]
   GSF: ???????        [cost ea. ?]
   ECP: 001440780   [45p exc vat ea]

* cylinder head to manifold copper nuts [8mm] (x8 )
   VW:  N 900 850 01 [?0.29 ea]
   GSF: ???????          [cost ea. ?]
   ECP: 001440610     [45p exc vat]

* manifold to downpipe studs [10mm] (x6)
   VW:  N 044 520 3 [?0.32 ea]
   GSF: ???????        [cost ea. ?]
   ECP: ???????        [cost ea. ?]

* manifold to downpipe nuts [10mm] (x6)
   VW:  N 102 090 05   [?0.21 ea]
   GSF: 20279 [8mm]  [?0.20 ea.]
   ECP: ???????           [cost ea. ?]


If anyone can fill in any of the blanks above I'd appreciate it.

It would also be good to know the actual sizes of the manifold to head studs and nuts and the downpipe to manifold studs and nuts. I suspect one is 8mm and the other 10mm, but not absolutely sure.

Cheers,

Chris

Chris,

Cylinder head to manifold studs ECP: 001440780 [45p exc vat]
Cylinder head to manifold copper nuts ECP: 001440610 [45p exc vat]

I went to a fixings/fastenings shop for the manifold/downpipe nuts, the old copper ones on mine were really badly rounded off. Got tough zinc plated ones that will quite a bit of punishment and fitted them with a lot of high temp copper slip.

If you mean spanner sizes, I think manifold to head are 12 or 13mm and the manifold to downpipe is 17mm. Not totally sure about copper nuts - in theory shouldn't corrode :dontknow: my old ones looked corroded, also were a right   to remove. Both the nuts were so badly worn they ideally want a 0.5mm smaller spanner size? Can only assume they had been reused a number of times.

Cheers

Thanks Mark, I'll update my previous post for future reference.

I am assuming then that the downpipe to manifold studs and bolts are a different size to the head to manifold items?

Anyone (Chudd?) still got the VW invoice for the parts you listed, or a rough idea of how much you paid? If the VW stuff is not much more I'll go with that, otherwise it looks like ECP.

Cheers,

Chris

Chris here we go , i have just filled in your missing prices where applicable .  I used my VW dealer for small things to save the ? petrol cost of travel to  GSF .  

Exhaust Gasket 4 pieces : 028 129 589 ?2.02 EACH
Studs x8 for the cylinder head to manifold: 044 411 5 ?0.57 EACH
Nuts brass x8 for above studs : 900 850 01 ?0.29 EACH
Studs x6 10mm for down pipe to manifold: 044 520 3 ?0.32 EACH
Nuts x6 for above studs for down pipe : 102 090 05 ?0.21 EACH

It would also be good to know the actual sizes of the manifold to head studs and nuts and the downpipe to manifold studs and nuts. I suspect one is 8mm and the other 10mm, but not absolutely sure

Down pipe stud is 10mm part number comes from VW Passat same size as MK1 but original part now discontinued uses 17mm spanner !. Head studs to manifold are 8mm nuts use 11mm spanner ! I think Rajan's part number was for a smaller engine as the studs were smaller .

It took a bit of research at my local dealer to get the above and i can assure you even the nuts are the right type and look like do it right now and never again!! you will see what i mean when you get them . Good luck with it mate ..

Oh and ps the part numbers begin with N all except the exhaust gasket that just has V .

Great Chudd - thats exactlythe info I need. Those prices don't look muh more than the GSF / ECP equivalents for most things so I may as well go with VW.

Cheers,

Chris