Exhaust manifold - She Blows!!

[Ceptor]

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?

[mk1]

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.

[golfvr6]

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  

[VeeDubGTI16v]

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!!

[Ceptor]

Thanks for the guidence, I'll let you know how I get on.

[Ceptor]

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.

[golfvr6]

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.

[Ceptor]

GolfVR6 I'm near Salisbury.

[golfvr6]

I'm at woking in surrey
Your welcome to come up for it if you want.

[Ceptor]

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!