Thread: TDI EXHAUST MANIFOLD

Originally Posted by PETER S

IS THERE AN EASY WAY TO REMOVE THE BOLT ON THE REAR NEXT TO BLOCK AT THE BACK THAT HOLDS THE EXHUAST PIPE ON ,NEAR THE BIG BRAIDED LINE ALSO HOW DO YOU REMOVE THE BIG BRAIDED LINE WITH OUT TWISTING IT AS I NEED TO REPLACE THE MANIFOLD GASKET. ANY HELP WOULD BE GREAT AS MY WIFE WANTS TO SEND THE CAR TO SIMS METAL IF I DON'T GET IT RUNNING SOON

Mines a 300 Tdi the 200 may be different

With a long socket extension from underneath 15mm from memory.

The block end of the braided line is 28mm from memory, if it's twisting then I would guess that the fitting in the block is turning rather than the hose unscrewing off the fitting. I ended up modifying a shifter to open up more as this was the only thing I could fit in there. When I was was putting it back together I found if you remove the whole frount section of exhaust pipe it's much easier to get at, I was going to get an open ender and cut it down but couldn't get one the right size.

I hope this helps

Tony

I've changed manifold gaskets without undoing the dump pipe/exhaust.

Undo the inlet manifold and lift away, then undo the exhaust manifold bolts and carefully lift away from the head, just enough to clear the studs and you can wiggle the old gasket off and a new one on (clean the head face up first)
There should be enough flexibility in the exhaust mounts to achieve this.

There's a reason I do it that way.
I hate the agro of undoing the flange nuts, particularly when a 3" dump is in the way....

What rick said.I did mine about six months ago plently of room to get the old off and new on.

I also used Permatex Ultra Black Hi temp RTV silicone gasket maker with the gasket just for a little bit of extra insurance plus it helped to keep the gasket place.Also I didnt torque it down straight away I let the RTV silcone dry for about an hour.

So far so good and also the first time Ive ever done it