8v GTI Manifold Removal

[mpseaman]

Hi, does anyone know how to remove the exhaust manifold on a 1996 mk3 8v gti? It sounds like my manifold gasket is leaking, but looks a knightmare to remove as the inlet manifold is right on top of it! Any ideas would be much appeciated!

[Crasher]

The manifold is removed from below. You remove the three downpipe to cat nuts/bolts (which will be extremely rotten and need replacing) and then the six 17-mm downpipe to manifold nuts (which can be seized on to the extent that the studs snap) and with the downpipe out of the way, you remove the eight 12-mm socket size nuts that hold the manifold to the head. The two centre nuts are the worst to get at, you need a reasonably long 3/8” inch drive extension bar and a 3/8” drive 6 sided 12-mm socket, a 12 sided socket will slip. Some of the lower nuts are only possible with a 12-mm spanner, again six sided. You must buy all new nuts and washers and they are not conventional nuts, they are copper coated and the studs must be coated with anti seize grease.

[mpseaman]

Thanks for the detailed reply! Is it possible the studs that hold the manifold to the head could break? They look extremely rusty!

[Crasher]

It does happen but not very often. I always drench them with releasing fluid and go very carefully, if they start to feel tight I get heat on them but you don’t have that luxury. If they are original they should be OK, it is when non original nuts have been put on dry that the trouble starts.

[Mark Litten]

Hi, I recently got my first golf, its a mk3 gti and i have a blowing manifold. Im having trouble removing the downpipe to get at the manifold, is there an easy way to remove it?
Im very grateful for any suggestions. I already have it disconnected, but theres no room to pull it out?

[Crasher]

You have disconnected the downpipe from the front silencer haven't you?

[Mark Litten]

Hi, yes, the downpipe is totally free, there is just no space to remove it, up or down?

[Crasher]

If the cat is free of the downpipe it can be pulled down far enough to allow the manifold to be removed from the head studs, if not then disconnecting the three engine mounts and jacking the engine up will help.

[Mark Litten]

Ok, i'll give that a try, many thanks for the advice.