Blowing from exhaust to engine gasket.

[Mr.Tom]

Okay, so the technical terms I don't know, but I seem to be getting some blowing from the gasket that sits between the engine and the downpipe to the exhaust.
Just got a quote from the garage near me saying it could be from around £50, up to £300 to do if there are any problems with bolts sheering (they say it is quite common?)

Is there a "good" way to do it myself? I would be a bit more happy to take my time than the garage who are pretty busy right now.

It's a late 96, P reg GTI 2 litre. I think the engine is AGG. Anyone got any ideas? The bolts I can see look a bit corroded :s

OR, would it be okay to get some exhaust sealant and get some of that around the join instead? Not too fussed about it looking pretty for now

[rubjonny]

main problem with this job is the inlet has to come off, and the bolts can be a pain to reach.  If its anything liek a MK2 you need an allen bit with a long thin extension to get to a couple of the inlet bolts. once they're off the exhaust nuts are relatively easy to remove, and since its quite a young car you should be able to get them all out without problems.  Dont count on it though!  I'd buy a set of 8 new studs 'just in case' plus you'll want 8 copper nuts. GSF do the studs & nuts

The trickyest zaust nut is the bottom one on cylinder #3, only tool you can get on it is a 12mm ring spanner. If it rounds off mole grips should get it but access is limited so you'll probably unleash some harsh language.

So in short, before you do anything make sure you can get to all 6 of the inlet manifold bolts.  Tap the tool in firmly, and if possible clean out the bolt heads as best you can. A mirror really helps here!
Then once the inlet is off, start with the nut I mentioned above, if that one comes off ok the rest should as well, and even if not you'll have much more room to atack them.  Sheared studs are not usually a problem, once the nut is off they should be pretty easy to wind out so long as you have enough of the stud to grip.

[sharki786]

USE LOADS OF "DOUBLE TT" ITS LIKE WD40 BUT BETTER AND LEAVE IT TO SOAK AND MAKE SURE YOU USE PLENTY OF IT, WHEN YOU PUT IT BACK TOGETHER TRY TO GET THAT OFF THE EXHAUST PIPES, AS IT WILL START TO SMOKE WHEN YOU START IT UP BE CAREFULL.

[gtigolfthree]

Yes exhaust manifold nuts are a pain because they get heated to such high temperatures then cooled as you start stop the engine.

[Mr.Tom]

So, would it be better to do it with the engine warm or cold?
Also, could someone give me a list of parts to get (type of bolts, length, which gasket to ask for)?
Thanks.
p.s. Who are GSF?

[rubjonny]

cold unless you like to be burnt 

http://www.gsfcarparts.com

11821 - INLET MANIFOLD GASKET - 2.40 x1
20279 - COPPER NUT-8mm - 0.30 x8

from VW:
N 0444115 - stud, M8 - 0.61€ x8 (you probably wont need all 8, but you never know!)
028129589B - manifold gasket - 2.3€ x4

[Mr.Tom]

Thanks.
Can I just confirm that the inlet manifold is correct? is states that it is for an A6 (I know it is same manufacturer and all, but want to be sure before I start taking the car apart )
Cheers.

[rubjonny]

yeah its deffo the one. trouble with gsf if you do a search on the part number it just pics up the 1st car its listed to fit in zee database!

[Diamond Hell]

You could just try tightening the existing nuts, as they may have worked loose.

Worked for me before.

[Mr.Tom]

I had a look yesterday, and it may not actually be coming from there. If I feel down by the join between the engine and gearbox, there is a breeze about half way down. :s Will try and get my camera in for pics.