Right.. I'm due doing my cylinder head gasket and am planning a top end rebuild at the same time (130k engine, not been done before) The manifold bolts are rusted badly, anyone have any pointers how to get them off?

Where can you buy new nuts/bolts? Are they specific items or a B&Q jobbie?

Exhaust Studs Part No. - N 0444104

They are M8X28

The best way to get them out it loads and loads and loads of PlusGas and a thin pair of mole grips.

Worse case scenario you snap one off then you have to drill it out the get the Tap&Die set out

Not sure if you have the nuts off yes but if you haven't then use a wire brush to clean the 15 years worth of crap to give you a fighting chance.

However there is a special tool for this and they are amazing/expensive

more than likely a few will snap but thats no real problem. I'd recommed not getting new normal studs and try to get some stainless steel cap heads or use a bolts and locking washers.

Awsome!! I'm scared!

So how are they fastened normally? Are they bolts or studs wound into the head and nuts to hold the manifold on?

the stud is wound into the head.

then the manifold is bolted onto the bit of stud that sticks out

part in the head. gap for mole grips. other part is for the nut to hold the mani in place

So in theroy you could mole grip the stud and wind it out carefully? and replace?

yep.

although 15 years of rust and mole grips that wont grip put your theory out the window

I can but try! Anyone know if its easier with the engine hot or cold?

definately cold.

you ever touched a manifold? only a couple hundered degress

I have.. I'd just be carefull!

Cheers for the advice anyway!

Should be starting tonight if the weather keeps up.

Oh one more thing.. Where's best to get the studs/nuts from?

GSF, ECP or VAG?

probably all the same stuff.

VW they are not even a quid each

Whhooooo.. cheap!

Does anyone know how many there are? I'm going to replace them all for good measure!

i think there is 5...

edit, looking at yoof's engine there are 5 nuts :)

http://www.clubpolo.co.uk/forum/index.php?showtopic=34365

Edited 20 August, 200719 yr by martinb

You want a 12mm 6 point deep drive socket if they are original nuts. If they have been replaced they could be 12 or 13mm. Wire brush and plus gas them after they have been warmed a bit.

Got them off very easily! Didn't even use plusgas or wd40!!?? I had troble with one, but a smaller socket hammered on did the trick!

Think i'll re-use the stems but get new nuts!

Cheers for the help guys!