Pat

I apparently have a leak in my exhaust manifold gasket, and am trying to figure out how to replace it. I didn't see anything in the FAQ or Google other than turbo swap instructions.
I'm told the exhaust system and everything needs to come out from the bottom. Is that right?
Anyone have a write-up on this? Any tips? Time required?

SilverA4Fun

the gaskets for the exhasut manifold. Cat and DP can stay, just unbolt hanger and turbo-cat bolts. With minimal removal, mostly jus the heat shield and oil line shield, you can check the manifold-block bolts they may be loose, thus the leak. Ditto for manifold-turbo bolts and gasket. If you end up remving the manifold you'll need to replace 3 gaskets:cat-turbi,turbo-manifold, manifold-block. Not a bad time to also upgrade to PnP manifold or K04.<ul><li><a href="https://forums.audiworld.com/a4/msgs/2322800.phtml">https://forums.audiworld.com/a4/msgs/2322800.phtml</a</li></ul>

ModifiedA4

removing the exhaust manifold itself is easy.

you do not have to remove any exhaust components.

just follow this <a href="http://home.comcast.net/~hhong4/k04install.htm">procedure</a>.

personally, i'd use new hardware everywhere.
-new cat nuts
-new turbo/manifold bolts
-new manifold nuts
-new supportbracket bolt
-new turbo/manifold gasket
-new turbo/cat gasket
-new oil line gasket
-new coolantline/oil line washers

a list of stuff can be found here:<ul><li><a href="http://www.modifieda4.com/web/projects.html">list o stuff...</a></li></ul>

Pat

The mechanic has already checked to ensure the bolts are tight. I have a K04 and PnP manifold. I guess I'll just be taking it out and replacing gaskets.
Thanks again!

Pat

What are the chances I'll run into something like a broken stud or frozen bolt or something like that? I just want to be sure this is something I can do myself and won't have to tow it to the mechanic half way through the job.

ModifiedA4

take the airbox out the night before, and spray the crap out of all the bolts so they soak for a night...the cat bolts, the manifold bolts, the turbo bolts.

also buy a NEW 6mm HEX key for the turbo bracket bolt.

if you dont have a 3ft extension for your socket set, get that too for the one hard to get cat bolt.

thats about it.

Pat

Chances are I won't do it for a month or so, but I'll be sure to post how it goes.
Thanks again, you've been a big help.

matt13

Luckily it was a clean break and I was swapping the turbo anyway.

neil1985

Hi could anyone tell me where I can find a mechanic to change my gasket by the turbo and how much this gasket cost. My email is sjacobsmedical@gmail.com

Many thanks