Exhaust Manifold - Advice Please

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Doggy
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Exhaust Manifold - Advice Please

Post by Doggy »

Forgive me for posting a non-pug problem, but I'm hoping someone has some suggestions for this one.

My son's 1.4 mk3 Golf, (AEX engine), had a leak from one end of the exhaust manifold / cyl hd joint. Muggins here tried to tighten it up with predictable results :oops: Now have 3 good studs out of 5 :frown: I managed to get one of the broken ones out, but the final one will need drilling. Engine is tilted forward slightly so you can only see it with a mirror and there's no hope of getting an ordinary drill betwixt cyl head and radiator housing.

I'm therefore tempted to try putting it back with 4 good studs. it has 3 along the top, (which are OK - centre & both exteme ends) and two along the bottom, (between 1 & 2 cyls & between 3 & 4) - this last one has the broken stump in the hole.

My questions are:

1. Any idea where I can get spare stud(s) on a Sunday?
2. Anything I can use to improve the chances of the gasket sealing with a less than perfectly even pressure on the fixings?
3. What's the chances of it holding on 4 out of 5 studs, if they're all in good nick?
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jasper5
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Re: Exhaust Manifold - Advice Please

Post by jasper5 »

This is a very common problem with that engine. :frown:

The stud threads should be standard 8mm, therefore any 8mm stud from any car will fit, if you cant find a stud use a standard 8mm bolt with a spring washer and a flat one.

If you have the manifold right off, buy some exhaust assembly paste and fit it between the gasket and the head and gasket to manifold with extra around the broken stud.

If it is at all possible, you might be able to drill into the aluminium part of the head next to the broken bolt and after tapping a new thread, file out the manifold hole so that you can get a new bolt in.....I did this a couple of months ago on a Nissan Patrol, the broken stud refused to drill out...broke several drills trying, so I drilled the aluminium part and threaded that filing out the manifold so that I could fit this new bolt.
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Doggy
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Re: Exhaust Manifold - Advice Please

Post by Doggy »

Many thanks for your help, jasper. 8)

1 tube exhaust assy paste £1.89, 3 inlet manifold studs from something oriental & unidentifiable at the scrappy, (foc - I offered to pay)....
Put it back together with 4 good studs out of 5 & plenty of gunge - sorted! :P
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
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Welly
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Re: Exhaust Manifold - Advice Please

Post by Welly »

dogslife wrote:Many thanks for your help, jasper. 8)

1 tube exhaust assy paste £1.89, 3 inlet manifold studs from something oriental & unidentifiable at the scrappy, (foc - I offered to pay)....
Put it back together with 4 good studs out of 5 & plenty of gunge - sorted! :P

Well done Daddy, err I mean Doggy!!

Did Sonny help/observe Daddy fixing the car so that he can learn/do it next time?
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jasper5
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Re: Exhaust Manifold - Advice Please

Post by jasper5 »

dogslife wrote:Many thanks for your help, jasper. 8)

1 tube exhaust assy paste £1.89, 3 inlet manifold studs from something oriental & unidentifiable at the scrappy, (foc - I offered to pay)....
Put it back together with 4 good studs out of 5 & plenty of gunge - sorted! :P

Excellent :P I've done this quite a few times on the Polo!
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Doggy
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Re: Exhaust Manifold - Advice Please

Post by Doggy »

Welly wrote:Well done Daddy, err I mean Doggy!!

Did Sonny help/observe Daddy fixing the car so that he can learn/do it next time?
What do you think? :frown:

Came out with some lame excuse about working from 2pm to 5am and claiming to be tired! :roll:

Bl00dy luxury!, I told him. We had to get up 2 hours before we went to bed, work a 27-hour shift AND pay mill owner to let us work there....
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
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jasper5
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Re: Exhaust Manifold - Advice Please

Post by jasper5 »

Speaking of daddy and son....my 16 year old son got a phone call at 6pm, he got an apprenticeship at our local Volvo dealers, he starts monday :P :D :mrgreen:
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Doggy
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Re: Exhaust Manifold - Advice Please

Post by Doggy »

That's great news jasper! Decent apprenticeships are a rarity these days, (as I'm sure you know).
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
Top
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Welly
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Re: Exhaust Manifold - Advice Please

Post by Welly »

jasper5 wrote:he got an apprenticeship at our local Volvo dealers
Cool, discount on parts for Welly :cheesy:
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teamster1975
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Re: Exhaust Manifold - Advice Please

Post by teamster1975 »

Good for him Jasper! I bet you're a proud man indeed! :D
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jasper5
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Re: Exhaust Manifold - Advice Please

Post by jasper5 »

Thanks, yeah i'm pleased for him.

At least I should be able to close down bank of dad now :twisted: :lol:

He was thinking of joining the Army, I'm chuffed to bits that he isn't :P

No problem with discounts, Welly :cheesy:
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