1.6 carb, exhaust manifold ring seal

[Haribo!]

anyone successfully managed to get an exhaust manifold for a 1.6 carb engine back on the down pipe without it blowing? ive got a brand new ring seal and new clips and it still blows, the only odd thing i noticed is that the old ring seal was like a really tight network of thin metal meshy stuff and the new one was a solid piece of metal but the vw garage insisted that the new one was a new and better one and that the old one was not genuine but its the same as ive seen before on that engine type....... any idea how to stop this blowing? should i bother fitting the old ring seal back in and hoping for the best? i would simply try it but i hate those C clips

[rubjonny]

did you manage to get the new seal to seat on the zaust fully?  I could never get the room or leverage to hammer it all the way on, in the end I gave up and put the old one back on with lots of zaust sealant.  If you got the metal ring all the way on, it will probably be quite tricky to get it off again, smear a load of zaust assembly paste on it & see.

Ideally you want to replace it with a proper GTI zaust as they seal much better!

[Haribo!]

yeah it slipped on quite easy, in fact i had trouble holding it on whilst trying to hold everthing els together to put the 1st clip back on, i was thinking being metal maybe it might expand when i finally get the car up to full heat, as i haven't yet due to the water pump problem, didn't use any sealant tho........ may be the problem

[gribsy2006]

ive got a 1600 driver and i was just wonderin if a full gti exhaust will fit on my driver anyone know?

[Haribo!]

yep indeed it will, as long as its an 8v one, I'm beginning to wish i had done that now to be honest, as its even more power to go with the rest of it, and it doesn't have this stupid seal ring thing

[gribsy2006]

so mate i have an 8v driver so do you mean only an 8v gti exhaust will fit or will an 16v gti exhaust fit my driver

[rubjonny]

only an 8v GTI zaust will fit.  You have 2 options, either fit a 1.8 Driver/GL downpipe & GTI system from the front silencer back, or fit a complete GTI system including the manifold & downpipe.

[Haribo!]

as rubjonny says and i recommend that you use the gti manifold because then you dont have to fool around with the part this topic is about

[gribsy2006]

will a 8v gti back box fit straight on to my 1600 driver in place of the original back box. is it a direct fit
cheers

[rubjonny]

no it wont, both the bore is too small, and on a 1.6 there is no rear silencer, backbox just has a long pipe to the front silencer.