Cracked Exhaust Manifold Temporary Repair

[Malc 45]

My exhaust manifold is cracked slightly on the top near the block on my gti6 205, obviously I need to weld it, but access is a nightmare, hence either engine out job or can the manifold be taken off with out removing the engine (looks a nightmare job)? i am planning taking the engine out in the winter to seam weld the bay/tidy up etc and I would like to just get the summer past before doing this, I know welding is the real fix but any advise on a temporary repair? Rather than double work.

[2052NV 24]

That "kneed it" instant metal stuff is quite good. If you can get in there and clean up the area around the crack really well with emery tape and then apply the putty it should be a goodin for a short term.

 

http://www.youtube.com/watch?v=_kenw2_ckVk

[Dizzee stuff 33 1 Cars]

It can be removed if you drop the front subframe

[welshpug 1,657]

Remove the inlet and rh engine mount arm, tilt engine forwards after removing manifold nuts, extract manifold from tunnel.

[cheesegrater 43 1 Cars]

I removed my subframe to take mine off, nice and easy then.

[Malc 45]

Subframe looks the best bet, (wp got lynx charger kit on so tilting not an option without removing the charger bracket)

 

Thanks all, good excuse to seam weld and paint the subframe while off.

[Tom Fenton 1,541]

Subframe is easier than you may think to get off really. Lower ball joints, track rod ends, drop links. Steering column uj. Gear linkages. Lower fork mount. Then 6 bolts and it is off.

If your steering uj is the later square drive type it can be swung 90 degrees very easily to disconnect it from the steering rack.

[Malc 45]

Dropped the subframe last night, (Tom your right a simple 30 minute job) then had the manifold off quite easily. Manifold is like a bloody sieve, three out of four branches had cracks, not impressed!! Also noticed a small crack in the down pipe, welder is really getting some use now. Decided to replace ARB bushes while subframe off, why does one job always lead to another on these 205s?

[welshpug 1,657]

Bushes are probably fine, they are poly as standard

[Malc 45]

They possibly are, however got a new set sitting in the garage, may as we'll swap over while access is easy.

[cheesegrater 43 1 Cars]

I'd be concerned as to why the manifold is in such a dire state,

[welshpug 1,657]

Floppy lower engine mount and/or poor welding?

 

As for arb bushes, hope you have genuime orange and blue type, nothing aftermarket seems to fit!

[Malc 45]

I am concerned, engines mounts are all uprated and new last year so I know they are fine, manifold was modded and welded by miles, again looking at the welds no real issues there, the manifold basically had very small hairline cracks across three of the four branches at the top opposite where welded underneath, any thoughts? Going to clean up and weld all around just to make sure.

 

New ARB bushes are the orange and blue ones as per currently on the motor,

[cheesegrater 43 1 Cars]

Definitely cracked? Not where the welds have been ground back? It would have sounded like a gatlin gun with that many holes! How well supported is the exhaust?

[dobboy 231 2 Cars]

Malc, did you tighten it previously to correct torque settings?

 

Things can be over tightened as well as under tightened.

[Malc 45]

Yeah definitely cracked, I'm guessing where it was bent down to give correct angle there has been stress there, the exhaust has been off an on a couple of times as I had issues with the center mount, so possibly this had led to the problem, all secured properly now though. Too be honest I was surprised it wasn't louder than it was, it was very small hairline cracks and you could just tell it was leaking. Anyway off now, and going to weld all around for more strength and leak test before it goes back on. Just waiting to see what the next problem will be with the motor, been a pig this year with various issues.