Hi,

This is following a previous post. I am experiencing a rattling/popping sound from my engine on a cold start. A reply in one of my other posts led me to check the manifold as he source for noise and fumes. This is definatly the source of my problem.

Do I need to change the whole manifold, or just the gaskets? If I do, how much would one cost me and is this a DIY job? I'm not very experienced with working on cars, but I do like to do most jobs I can myslef..... its the only way I will learn.

Can anybody please provide me with a rough guide to removal and replacement?

Thanks in advance!

I've never heard of the manifold cracking etc, so your manifold should be fine. Just replace the gasket.

VW are the best gaskets as they have little metal rings in. Although at £10 a piece (and you need to pieces) I refuse to pay that so I've always ran GSF/Eurocar parts with no probmlem (they are 3quid a piece). My method means taking the manifold and downpipe apart so get a new gasket for that too (about 5 quid max)

It is an easy job if you have no problems. Which i'm guessing it wont be.

First thing first, jack the car up and get under the car. Where the manifold meets the downpipe there are x4 nuts.Undo those and seperate the downpipe and manifold (may take some force to get apart)

Now there are 5 nuts holding the manifold onto the engine.. Undo those. The manifold should come off from the head. Might be tough too.

Now, lets say the manifold is off.. Pull/prise at the original gasket (it will probably need scraping off as it'll have baked on over the years) off the head and manifold and make sure both surfaces are pretty clean.

Inspect your exhaust studs (these are the studs with thread on that allow you to bolt the manifold on) check the studs on the engine and the studs that connect the manifold to the head. If they look rusty and old, replace.. Now I would always replace for what they cost. Get down to GSF for some copper nuts and new studs (like 10 quid for the entire set) Be aware that the studs and nuts are different sizes for the head and for the manifold to downpipe.

The studs should just twist out using mole grips and the new ones go in using mole grips (be very careful not to damage the new studs.. Try wrapping in a old cloth first)

Once your happy with the studs, rest the new gaskets on the head (will fit on and stay there) Put manifold on, tighten new nuts to studs, dont go overboard as you dont want to thread one.

Place the gasket for the downpipe/manifold.

Fasten downpipe to manifold.. Tighten.

And now test!

Now... Problems you may occur...

You may round some nuts or at the very worse snap a stud. If you round a nut, use mole grips or hammer on a socket (so its a very tight fit), that method always worked for me.

If you snap a exhaust stud, you may be lucky and leave enough to grab with mole grips, or you could snap it inside the head. Which means either drilling it out or buying a stud/bolt retractor thing, kinda like a reverse thread drill bit that digs into the stud but screws its out at the same time. Thats the cleanest and safest way. If you mess this up you may damage your cylinder head and then your fucked.

So be careful..

Its realistically a 1hrs job if your doing it for the first time and you get no problems.

So dont worry too much.

Good luck!

Edited 31 December, 200718 yr by MrP

Oh.. I would also say that it'll cost you 30quid max.

10-15ish for the gaskets

10-15ish for new studs and nuts.

If you can, assault the exhaust manifold nuts and studs with WD40 or Plusgas for a good few days (and regularly) beforehand.

These aerosols are penetrant oils/substances, they are designed to find their way down into rusted threads and mechanisms and weaken them, these can make the difference between a bolt coming out, or a bolt snapping out. They need time to work to their best - before I brought my car down to the garage for front suspension, I treated all potential danger bolts with a prescription of WD40 everyday for about 4 days beforehand. When it came down to removing these fixtures, they were all good as gold.