Exhaust manifold gasket replacement, detailed with pictures. (Page 3/6)
doublec4 FEB 21, 10:35 PM
Awesome write up, I plan on porting my manifolds soon and now I dont have any questions on the process

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jetman FEB 22, 01:54 PM
Thank you very much for the kind words. It's nice being appreciated for making a meaningful contribution to the forum. Believe me, it's actual knuckle busting, back twisting, arm scraping experience doing the talking here, not to mention a bit of grease and oil on the keyboard.

I can't stress enough, be prepared with tools, back up plan, taking it in smaller and more manageable tasks over the course of several evenings or weeks, what ever suits you. I kept my daily driver on the road uninterupted by doing a little work at a time, it was alot less frustrating for me too.
Good luck on the repairs.
docbob FEB 22, 03:15 PM
Great thread lots of good info, I'll be using it as my guide in the near future.
Thanks "Doc" Bob
Notorio MAR 26, 09:39 PM
Super write up. I'm also bumping this so I can put in My Favorites. (It would be nice if there was another way to do this ...)
Knight APR 05, 10:11 PM
I feel better about trying to tackle this myself now. I also now how to prepare for this job and a plan of action.
I just got my exhaust system fixed as I had a 4" gap between the down pipe end and the cat. Now that it is not as loud, I hear a loud popping - the " oh crap is that a cracked manifold or did I just blow out the gasket" sound. I just had it fixed yesterday and it is rapidly becoming worse. I fear I need to fix this as soon as I can because of the fear that It may be more serious. Could the manifold bolt have snapped? Can I hurt anything with a severe leak?


jetman:
+ for you!
jetman APR 06, 12:51 AM

quote
Originally posted by Knight:

Could the manifold bolt have snapped?

Can I hurt anything with a severe leak?



You can inspect with a small trouble mirror to look for snapped bolts and cracks. You can pick up an inexpensive articulating mirror at most auto parts stores. I use a "MIT" Michigan Industrial Tools, 2-Pc. inspection & pick-up tool set, $3.99 at Murrays Auto Parts Stores. Both the mirror and the magnetic pick up tool are telescoping.

The bad thing about an exhaust leak is that you have red hot exhaust gas exiting the manifolds in an uncontrolled fashion. You are at risk for fire so you do need to take care of this soon. Remember that you have plug wires, main wire harness, sound insulation, vacuum lines and even your fuel lines in that general area that can burn up fast. I'm sure that you already knew that, I was in denial about facing the manifold job myself.

I'm going to re-post this paragraph because it bears repeating.

The most important aspect of this job, in my mind, was not to try to tackle it all in one afternoon and plan ahead. Several parts of this task were done on different days and evenings. I was still able to use the car between the different stages of work. If I had snapped a bolt, I would have stopped, drilled it out, then moved forward again. Same thing if I had a cracked manifold, I had shops lined up to do the welding work in a pinch if needed.

Exhaust manifold gaskets are a PITA job especially on a 20-year old car, just take it in stages. If you run into difficulties, start a thread, lots of here can post suggestions to help you out. Thank you for the accolades.

Hudini APR 06, 12:58 AM
When I bought mine it had a bad leak. The rear window would get so hot you couldn't hold your hand on it. Some of the engine wiring harness was damaged too. After awhile (180 miles on the interstate) the ignition module died. Yes, it can damage something although it depends on the severity and the location.

If you have time and really want to use good gaskets, try these:


Fits a 1966 Type 1 Volkswagen. About $1.50 each.
Gecko MAY 29, 01:48 PM

quote
Originally posted by Hudini:

When I bought mine it had a bad leak. The rear window would get so hot you couldn't hold your hand on it. Some of the engine wiring harness was damaged too. After awhile (180 miles on the interstate) the ignition module died. Yes, it can damage something although it depends on the severity and the location.



Lately there has been a sound that I thought was an exhaust pipe vibrating, or loose or something, and the local shop looked at it and told me its the manifold gasket. So its now at the shop having the manifold gasket replaced (now I wonder if they are doing one or both). I have recently been told that my car was pretty warm or gives off a lot of heat (from someone standing next to it). I just recently had to replace the ignition module too. Hmmm this all seems to match what you said above.

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"what you've just said is one of the most insanely idiotic things I have ever heard. At no point in your rambling, incoherent response were you even close to anything that could be considered a rational thought. Everyone in this room is now dumber for having listened to it. I award you no points, and may God have mercy on your soul"

Knight JUN 04, 12:43 AM
What about the header to y-pipe connection? I can't seem to find the gaskets for that.
jetman JUN 04, 08:42 AM

quote
Originally posted by Knight:

What about the header to y-pipe connection? I can't seem to find the gaskets for that.



No gasket required as the connection is supposed to be able to articulate. Tighten down the bolts snugly but do not overtighten, the joint has to be able to flex somewhat. This helps keep the manifold from cracking, or so I've been told here on the forum.