Removing Gti-6 Manifold

[Joshy 0]

Is there a enlightened way to get the exhaust manifold off of a GTI-6 engine whilst it is in a 205 engine bay, or am I on the right track by swearing, cutting up my chubby arms by trying to squeeze them between the bulkhead and the manifold and then swearing some more? There is literally bugger all space! I've had some thoughts about unbolting the manifold from the downpipe and removing the manifold with the head, but I'm HOPING that will be unnecessary?

 

And while I'm asking a stupid question. What exactly holds the cambelt cover on? I've removed 4 Allen bolts (Two at the top, two at the bottom sides by the crank pulley) and the two 10mm nuts, but it still seems to be held on somewhere on the bulkhead side of the car.

 

And the final stupid question - I was told by a reliable source that the cambelt was changed recently just before I bought the car, although from the history I have with the car I cannot. Should I really bite the bullet and do the CamBelt, water pump and tensioner again for my piece of mind, especially considering I'll be rebuilding the Head/Fitting a good replacement head on this strip down? I just REALLY don't want to because of the lack of space (is it even possible to do with the engine still in the car!?)

 

Other than the above issues, things are going rather well!

 

Thanks

 

Josh

[pugpete1108 62 1 Cars]

may well be an engine out jobby i'm afraid. i know there is no way of getting mine out without moving the engine .

 

maybe you can drop it out the bottom if you move the subframe and rack etc. but its still hard work.

[welshpug 1,666]

There's 3 allen keys at the top of the cover, no need to remove the bottom ones as the cover just slides over them.

 

 

As for the manifold, do you need to remove it from the car or just off the head?

 

If the head is coming off them you do need to remove the manifold, you'll never get the lower branches out past the block.

 

If the head is staying put I do believe you can get them out from underneath by removing the subframe, otherwise its an engine out job.

 

Would have thought it is possible to do the belt in the car, but for how long it takes to whip the engine out and how little time it takes to do it out of the car I'd be tempter to take the engine out.

[DrSarty 90 1 Cars]

An EW cylinder head is very similar to a GTI6 head, i.e. with the two plastic cam covers, and I was confused too.

 

Once you've removed every bolt (and I seem to remember there being about 8-10 on each one), it holds on for dear life unless you carefully free it with some tapping and leverage with a dead blow hammer or drift and a blade.

 

Ref the exhaust: yep, it's a bastard. Can be done from underneath on a ramp with extension bars and wobbly sockets, on top of scratched arms, leaning, ratchet spanners, sockets and swearing.

 

I'd agree with Pete. Engine out is less pain in the long run.

[marksorrento205 80]

I have just swapped my gti6 exhaust manifold in my 205 no probs. I took off the subframe inc steering rack and the o/s driveshaft, left on the wishbones and the rest of the exhaust system on inc downpipe and I had loads of room

 

Edit: I left the engine on the mounts apart from the lower one which was removed to remove the subframe.

Edited March 7, 2010 by marksorrento205

[harryskid 193]

Do i take it this would be the same for a zsara engine in a 205 as well

[marksorrento205 80]

If its a zsara vts engine, its the same engine, and even if you have the later type manifold (which I doubt due to the flange to the downpipe being different ) they are roughly the same size - so yes

[Joshy 0]

 

I did think things were going a little TOO well, not really the stuff I wanted to hear

 

Taking the engine out is not really an option, nor is getting it on a ramp or leaving it in pieces seeing how I have (perhaps foolishly now that I think about it) attempted to do the job on the roadside, so the car has to remain semi assembled so that it is safe to leave for a few weeks while I go about sourcing parts.

 

Are we then saying that removing the manifold it is "impossible" to do from above, or can it just about be squeezed with enough patients and swearing? I'm "just" removing the head, so the manifold does not need to come out, just away from the Head.

[welshpug 1,666]

As I said, if you only need to remove the head then it is possible to remove it from the head and leave it sitting on the subframe still attached to the downpipe and take the head off.

[Joshy 0]

Thanks for the info guys, I'll continue struggle at the weekend, at least I know it is possible.

 

Anyway, I thought I'd bump this thread and ask another odd question, rather than start another - Cambelt change with the engine in situ, Is it as impossible as I imagine? Surely I might be able to squeeze it?

Edited March 10, 2010 by Joshy

[pugpete1108 62 1 Cars]

Thanks for the info guys, I'll continue struggle at the weekend, at least I know it is possible.

 

Anyway, I thought I'd bump this thread and ask another odd question, rather than start another - Cambelt change with the engine in situ, Is it as impossible as I imagine? Surely I might be able to squeeze it?

 

i'm sure it can be done in situ, but be prepared for no skin left on your knuckles and backs of your hands

 

i wouldn't personally, but seeing as you have little choice i guess you have to.

 

you might need to drop the engine a little to access the tensioner etc but not 100% on that