AAZ exhaust manifold dramas

Post by **swell2316** » 06 Oct 2008, 20:11

Hello all, I've had a AAZ conversion and just lately I found it blowing a little from the manifold so i tried to check the nuts for torque and one of them sheered off. I know that the air cooled exhaust studs could be screwed out and replaced with new ones, is it the same for the 1.9td or am I in a world of Chit?

Post by **nindy** » 06 Oct 2008, 21:21

Pretty sure you can get them from vw have a look at vagcat online or try brickyard forum matey

Post by **skell** » 08 Oct 2008, 12:17

manifold may well need flanges flattening, machine shop job or like this
https://club8090.co.uk/wiki/Te ... ting_faces

Post by **swell2316** » 12 Oct 2008, 13:16

Just to keep you informed I got a set of studs from Russel at Syncro Nutz (cheers Russ). I then set about striping the exhaust end of the engine. this bit is not easy as there isn't a great deal of space. I removed the exhaust, the down pipe, then the turbo. With all this out of the way I could get easy access the manifold. I removed the manifold and then set about removing all the studs from the block. I found that the Mole grips and WD40 method of stud removal (descibed on the forum) was not a route I wanted to go down as I wanted a more dependable method and so used 2 x m8 nuts tightened against each other on the stud using a ring spanner and a socket then sliding the socket over both nuts I was able to extract the studs with ease. The offending stud that had brought me to this place had sheered at an oblique angle and wouldn't accept the nuts so I had to file it down to flatten the end, I then did the same with this one and it came out no drama. All the parts removed were then replaced and I can say that the blowing manifold is no more. thanks to everyone for the advice.

Post by **spannerboy** » 10 Nov 2008, 21:40

check it is not blowing through the heatshiled nuts

Post by **ringo** » 10 Nov 2008, 22:07

swell2316 wrote:Just to keep you informed I got a set of studs from Russel at Syncro Nutz (cheers Russ). I then set about striping the exhaust end of the engine. this bit is not easy as there isn't a great deal of space. I removed the exhaust, the down pipe, then the turbo. With all this out of the way I could get easy access the manifold. I removed the manifold and then set about removing all the studs from the block. I found that the Mole grips and WD40 method of stud removal (descibed on the forum) was not a route I wanted to go down as I wanted a more dependable method and so used 2 x m8 nuts tightened against each other on the stud using a ring spanner and a socket then sliding the socket over both nuts I was able to extract the studs with ease. The offending stud that had brought me to this place had sheered at an oblique angle and wouldn't accept the nuts so I had to file it down to flatten the end, I then did the same with this one and it came out no drama. All the parts removed were then replaced and I can say that the blowing manifold is no more. thanks to everyone for the advice.

Thanks for the update - its nice to hear of a success!

Did you just change the gasket or get the manifold machined?

Ringo