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Downpipe/Manifold Exhaust leak?



as far as the impact thing. i've found that using a single long 3/8
extension to get up there makes the impact much more effecctive. using 1/2
extensions (more weight), or multiple 3/8 extensions (more play), reduce the
effectiveness of the impact.
i use the mongo sears 1/2 drive impact at 100 psi, with an immediate step
down to 3/8, and have never had to leave it on any of those manifold bolts
for more than a few seconds, although i do a few rounds of pb blaster prior
to removal.
i get the same thing you described - some come off with studs, some dont.
Al

----- Original Message ----- 
From: "T. Reed" <treed2@wsu.edu>
To: "Joshua Hignight" <joshhignight@techography.net>
Cc: <scirocco-l@scirocco.org>
Sent: Saturday, December 20, 2003 1:53 AM
Subject: Re: Downpipe/Manifold Exhaust leak?


> I'll second that.. the studs and nuts can be a royal pain after almost 20
> years of rust and exhaust temperatures.
>
> I fought a 3 day battle about four years ago trying to get them off. Half
> of the studs came out attached to the nuts and the other half - well, I
> left them undisturbed until I did my engine swap when I replaced them. I
> was afraid of breaking them off by trying to remove them with the manifold
> attached.
>
> I succeeded in moving the studs/nuts only after hitting them with a
> liberal spray of liquid wrench about 8 days in a row, several times a day.
> I went through almost a whole can of the stuff, but it definitely helped.
>
> I think I wire-brushed some of the rust off, too. That allowed the
> penetrating oil to get down in to the threads a bit, I recommend
> torching/cooling cycles in combination with the liquid wrench. Just
> remember that the liquid wrench stuff is semi-flammable and it stinks
> pretty bad when it burns. The smell gets absorbed in to your skin and
> clothing very easily.
>
> I would take the wobble-extensions + hand ratchet route (you definitely
> want 1/2" drive) before impact. Stripping or breaking any of the fasteners
> is going to make your life miserable -quick-! I tried to use an impact
> gun but none of them even budged. After more liquid wrench, heat, and
> breaker-bar action, however, I was able to get them to turn out a couple
> of revolutions over 60 seconds or so of constant impact-ing. I was
> then able to work them out slowly with a hand ratchet.
>
> BTW its a pain to get the extensions fed up around all the obstacles. If
> you can get the heat shield off (you'll probably have to cut the bolt) of
> the downpipe you'll probably have a much easier time.
>
> You will want a new gasket, new studs and new nuts to do the job properly.
> Should be around $10-$15 for everything.
>
> HTH
>
> -Toby
>
> On Sat, 20 Dec 2003, Joshua Hignight wrote:
>
> > Watch out for the studs and nuts on the flange. I just replaced my
> > downpipe and two out of the 6 studs either broke or stripped. not a
> > fun or cheap thing to deal with. Also, the old O2 sensor is usually a
> > pain to remove. You're probably best getting a new one if you can't
> > easily get the old one out.
> >
> > peace,
> > Joshua
> >
> >
> >
> >
> > > Several people have replied with good advice on replacing the flex
> > joint....let me give some on trying to repair the leaking unit that's
> > on there now:  don't.
> > > BTDT
> > >
> > > Larry
> > >   ----- Original Message -----
> > >   From: James S. Danda
> > >   To: scirocco-l@scirocco.org
> > >   Sent: Friday, December 19, 2003 5:24 AM
> > >   Subject: Downpipe/Manifold Exhaust leak?
> > >
> > >
> > >   Hi,
> > >   I'm new to the list. I apologize in advance if this is a redundant
> > question.
> > >
> > >   I have a 1986 16v scirocco and there is a leak in the downpipe. I
> > can't see where it is coming from, but I can feel the exhaust leak at
> > a flange point between the exhaust manifold and the downpipe. Its not
> > at the gasket, its in the 'shock thingy' that absorbs the twist of the
> > engine. I'm guessing the downpipe fits in this shockabsorber and a
> > gasket of some sort needs replacing. Since I cant get a good look at
> > it and have never seen one before, I am only guessing.
> > >
> > >   Is this common and a DYI fix? Do I need a complete downpipe or is
> > there a gasket in there that needs replacing?
> > >
> > >   Thanks!
> > >   Jim
> > >   _______________________________________________
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> > >   Scirocco-l@scirocco.org
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> > >
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> > >
> >
> >
> >
> > --
> >
> >
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