GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Topic started by: Ceptor on 22 January 2004, 10:00
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Hello All.
I hope you can help with an annoying problem with my 1988 Mk 2 Golf 1.6 carb engine non cat (Code RF) LHD.
I have had the car for 3 years and it has always had a very noticable exhaust blow from the manifold area. It has a new VAG exhaust which made no difference to the blow. This is most noticable on acceleration when it is quite loud. But it did pass it's MOT twice like this.
It has one of those down pipes with the 2 spring clips and when I removed it the sealing ring was a braided type but the VAG dealer said I should have a new all metal sealing ring. I think the leak is from the sealing ring area and not the manifold to head.
Should I try the braided type ring?
Could the manifold be cracked?
Would a manifold from a 1.8 GTi Mk 11 fit my head and would a twin down pipe fit to the rest of my exhaust system?
Hope you can help.
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try to find out where its comming from when the engines cold wipe your fingers round the joins of the manifold to downpipe and on the manifold if you can see black soot or you get back soot on your fingers this is where it is blowing!
or start it from cold and then very quickly before the maifold get hot again put your hand near the joins of the manifold and downpipe if your feel air blowing on your hand youve found the leak!
theses problems can be hard to find....
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get some tissue paper and place it near the suspected exhaust leak.
if the papers blows away then there is a leak in that area
worth a go :-\
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the place you say is normally the common fail spot for exhaust leaks. next time you wash the car and before the exhaust is hot put some of the suds on the area around the join.
If it leaks you'll get bubbles forming.
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Thanks for the replys. If this is a comon fault is it possible to fit a manifold from a 1.8 16v to this 1.6 engine and use the twin down pipe to connect to the rest of my zorst?
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I believe an 8v manifold will fit, is the 16v the same size? If so I think you'll have to get a 8v exhaust to go with it as I think the end of the manifold is different on the 8v and 1.6, but I'm sure any decent exhaust place could put together something to make it fit.
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16v manifold won't fit, 1800 8v gti stuff will.
Steve.
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including camshaft! ;)
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and i shall soon be able to say wot difference it makes lol
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faster :P
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I have located the blowing noise to the manifold to head area and am now trying to remove the inlet and exhaust manifolds which I'm not finding easy since theyre both at the back of the engine.
Do you need a special tool to remove some of the exhaust manifold nuts? I have removed the 4 outer and the two inner-lower but I carn't see the two inner-upper, they seem to be hidden in a narrow space between the inlet and exhaust manifolds - is this right?
All I can see is 3 socket head cap screws on each side which seem to hold on the inlet manifold, however the middle ones are much longer than the 2 outers - does this middle one double as a screw to hold on the inlet and exhaust manifolds?
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I would think about taking the head off to replace the gaskets. The exhaust manifold nuts were 12mm, some have now corroded away to round blobs that you have to get imaginative to remove them ;). Not a lot more work than struggling away getting >:( >:(. Head set has all the gaskets you need and you can give it a clean up while its off.
Steve.
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If i remember right, the inlet manifold bolts on the carb models are really hard to get at, and very tight, and being allen key bolts will round easily.
I think you need to remove the inlet manifold before you can get to all the bolts on the exhaust manifold, if my memory serves me right.
I would try and get them off with the head on, if they won't come off then you will probably have to take the head off.
Plenty of WD40 needed ;)
Another tip, try coca cola on rusted in bolts, it works a treat, and no i'm NOT taking the piss :D
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i had to do that its a b!tch of a job. like vr6 said the allen key bolts on the inlet manifold are very tricky to get to. you need very small fingers!! ;D
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Thanks for the guidence, I'll let you know how I get on.
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I have now removed the inlet and exhaust manifolds and it is a difficult job, you need a long allen key about 8 inches, the inlet has to come off first. The exhaust manifold has a hair line crack in it along the top for about 3 inches. In addition 2 of the gaskets were leaking.
I have taken the manifold to a welders to see if it can be repaired. A new one from VAG is .... ?175 plus VAT.
I have also removed all 8 studs that hold the ex manifold on ( 2 sheared off when removing the manifold) but luckily I was able to extract them. I will replace all the hardware with new.
I also found that one of the core plugs in the inlet manifold was very thin and will also need replacing.
Will keep you advised.
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Where abouts are you mate?
I got a exhaust manifold of a 1.6 carb in my shed.
I think it is in good nick, i think it was the inlet manifold that was f**ked.
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GolfVR6 I'm near Salisbury.
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I'm at woking in surrey
Your welcome to come up for it if you want.
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GolfVR6 thank you very much for the offer, I'll let you know how I get on with the welding firm but if they don't come through then I may very well need that manifold!
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GolfVR6 I've sent you a PM.
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I've now finnished the job.
I collected the weld repaired manifold today, crack 3" long welded up. I then refitted the manifold (left the down pipe attached) and inlet manifold using new hardware, nuts etc, the VAG supplied manifold nuts are brass to prevent corrosion - much better than the original.
While the two manifolds were off I also changed a split CV boot inner (o/s) - good access. Some confusion on my part about the reassembly - see my other post 'CV inner'.
Refitted carb, pipework and water and started the engine.
Success, first time in 3 years that the car hasn't sounded like a tractor on it's last legs.
Thanks to all those who gave me guidence and to GolfVR6 for the offer of a replacement manifold, not needed at the moment, but you never can tell!
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Glad to hear that its ok ;D.
Steve.
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Nice one.........I thought these manifolds were cast and couldn't be welded.......or was it braised? Did it cost much to have done?
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I don't know the exact type of weld except that it's a skilled job to weld cast iron. The cost to repair a 3" hair-line fracture was ?20. You would probably be better off to track down a s/h good manifold rather than repair one but I needed to get the car on the road asap. A new one from VAG with VAT is ?200......I think they keep the prices high to force people to eventually accept that the cars are beyond economic repair so they will buy new/er ones.