Exhaust Manifold Gasket Replacement 8v GTI

[Whaleshark]

Just my thoughts having just done this.

I had a ticking noise that sounded like tappets from inside the car but under the bonnet, I thought I could make out air leaking so I suspected it was the manifold gasket. 

To the 'Search' button!!    There are a lot of threads if you search for 'exhaust manifold' and they are all useful but if anyone that is as similarly clueless as me is looking, this is what I would have liked to know before I started - to back up the other more established threads.

#   I couldn't identify any leaks, neither through wiping my hands around the exhaust looking for soot, nor feeling for the air coming out.

#   The best way to get to the exhaust is to remove the inlet manifold first.

#   I didn't remove the injectors and their bus bar but it would have made it easier as getting inlet manifold out is a bit tight.

#   USE A MIRROR.  This is the big one It makes a world of difference.  I didn't see it mentioned in the other threads but when removing the inlet manifold especially, it is invaluable.  (6 x 6mm Allen Key bolts.) 

#   My exhaust manifold connector to downpipe is the one with the 6 studs into a flange plate.  There is a flexi bit just underneath this which gave me enough room to change exhaust gaskets without undoing those studs. 

#   The whole job did take up most of 2 days - but I am no mechanic.  The bits - exhaust and inlet gaskets, 2 replacement studs(which came out with 2 of the em nuts), 8 nuts and washers came to about £17 from VW Heritage and TPS.  Replace em nuts with proper copper lock nuts. 

#   Problem is cured.


Cheers,
Whaleshark

[CanisLupus]

Hi, thanks for the info.

A few months ago I changed my tappets as it was getting very tappety at start-up and would take about a good 5-10min to go away. Since then, and it may have also been before I changed them I can always make out a tick tick tick sound which can get quite loud when going up hills.

Makes me think I may have the same problem? TO bad I only last weekend changed the inlet manifold gasket lol, was contemplating if I should take the exhaust mani off too but looked at the nuts and said I'll do it another day...

The ticking you had and which is now gone, was it very subtle when cruising, nearly not hearable, but when putting your foot down or especially going up hills, was it more pronounced? And the ticking intervals got quicker the higher the rpm?

Couldn't see any cracks or anything on my mani, and I can also swear I think I hear a leak, but feeling and looking can also find nothing, no soot no air.

[Whaleshark]

Hi, thanks for the info.

A few months ago I changed my tappets as it was getting very tappety at start-up and would take about a good 5-10min to go away. Since then, and it may have also been before I changed them I can always make out a tick tick tick sound which can get quite loud when going up hills.

Makes me think I may have the same problem? TO bad I only last weekend changed the inlet manifold gasket lol, was contemplating if I should take the exhaust mani off too but looked at the nuts and said I'll do it another day...

The ticking you had and which is now gone, was it very subtle when cruising, nearly not hearable, but when putting your foot down or especially going up hills, was it more pronounced? And the ticking intervals got quicker the higher the rpm?

Couldn't see any cracks or anything on my mani, and I can also swear I think I hear a leak, but feeling and looking can also find nothing, no soot no air.

Exactly this.  I am a bit wary of saying that is what you have as I would hate for you to go through the pain of changing the exhaust gaskets on my say so only to find that it isn't it!!!

Mine was a bit louder than yours by the sound of it, but it did seem worse on start up (like tappets), worse under load(like tappets) and worse at higher revs(like tappets).    Also, as I mentioned before, I couldn't find any soot or feel leaks.  Perhaps you only find soot if the engine is an oil burner? 

If you do take the plunge to do it then take comfort that my exhaust manifold nuts all came out without rounding, I did try and use the hex sockets not the multi sided ones where possible - if you know what I mean. 

If you don't do it then the other solution I found before I fixed it properly was to turn up the stereo a bit louder.   

[clipperjay]

You know these cars are over 20 years old now and I would say if the noise goes after a decent warm up the oil sump pump might be struggling to get oil to the head!
I would rather spent some cash on a sump gasket, drop the oil pump out, clean it out & the strainer which is garanteed to have some sort of dirt on it, then bolt it back up!
Either way if its never been cleaned out after all these years its a must so the head doesn't starve itself of oil later on.

Old mans way to check for manifold leaks is tear some tissue paper and go along the joins to see if anything makes it move about much eaiser to spot than trying to feel for leaking gasses 

[Turbotezz]

Old mans way to check for manifold leaks is tear some tissue paper and go along the joins to see if anything makes it move about much eaiser to spot than trying to feel for leaking gasses 

Hard to do due to the heat shield for the inlet. I have a similar problem, sound like an old aircooled beetle or something when under load. Have noticed however that its not there from cold, but within minutes comes it. Not sure if its pinking?