91 Golf 8v exhaust replacement

Hi all,
I have a 91 golf gl 8v. The exhuast has at least one leak, a shot
muffler, and annoying rattle that has finally gotten the better of me;
so i'm replacing it this summer. I'm going to start ordering parts
soon and I'd like to know if you guys had any tips or things I will
find out I need half way through.
I plan on replacing everything except the cat, manifold and on.

I've been reading and it sounds like manifold cracking is a fairly
common symptom for older cars (I just passed 170k).
From what I've read, I should be on the lookout for an 8v dual pipe
manifold? What year range will fit? Can I get this new/order from
somewhere or do I need to spend some time in a junkyard?

-Matt

The only problem I can think of is removing the two mufflers. They are
usally rusted and hard to remove so just cut them of. Clean the joint and
use some exhaust sealant on the joints when mounting the new one. Also check
the rubber mounts!!

SFC

"mini chifa" > schreef in bericht
...
> Hi all,
> I have a 91 golf gl 8v. The exhuast has at least one leak, a shot
> muffler, and annoying rattle that has finally gotten the better of me;
> so i'm replacing it this summer. I'm going to start ordering parts
> soon and I'd like to know if you guys had any tips or things I will
> find out I need half way through.
> I plan on replacing everything except the cat, manifold and on.
>
> I've been reading and it sounds like manifold cracking is a fairly
> common symptom for older cars (I just passed 170k).
> From what I've read, I should be on the lookout for an 8v dual pipe
> manifold? What year range will fit? Can I get this new/order from
> somewhere or do I need to spend some time in a junkyard?
>
> -Matt

Sawzall works wonders here! <G>
Junkyard on the manifold and downpipe might save you a few bucks, or ebay
might work for you too. That is IF you need them. Of course watch out for
rusted or breaking studs on that cylinder head and use new gaskets and brass
locking nuts.

Are you going with a stock exhaust or do you want something more?
http://www.techtonicstuning.com/ should have something more.
Stay away from those chain muffler places unless they are installing the
exhaust that you purchased somewhere.

JMHO
--
later,
(One out of many daves)

"SFC" > wrote in message
...
> The only problem I can think of is removing the two mufflers. They are
> usally rusted and hard to remove so just cut them of. Clean the joint and
> use some exhaust sealant on the joints when mounting the new one. Also
> check the rubber mounts!!
>
> SFC
>
> "mini chifa" > schreef in bericht
> ...
>> Hi all,
>> I have a 91 golf gl 8v. The exhuast has at least one leak, a shot
>> muffler, and annoying rattle that has finally gotten the better of me;
>> so i'm replacing it this summer. I'm going to start ordering parts
>> soon and I'd like to know if you guys had any tips or things I will
>> find out I need half way through.
>> I plan on replacing everything except the cat, manifold and on.
>>
>> I've been reading and it sounds like manifold cracking is a fairly
>> common symptom for older cars (I just passed 170k).
>> From what I've read, I should be on the lookout for an 8v dual pipe
>> manifold? What year range will fit? Can I get this new/order from
>> somewhere or do I need to spend some time in a junkyard?
>>
>> -Matt
>
>

I plan on going with a stock exhaust. I'm only planning on keeping the
car a few more years. But if a few extra bucks will get me something
worthwhile i'll go for it.

-Matt

mini chifa > wrote:
> Hi all,
> I have a 91 golf gl 8v. The exhuast has at least one leak, a shot
> muffler, and annoying rattle that has finally gotten the better of me;
> so i'm replacing it this summer. I'm going to start ordering parts
> soon and I'd like to know if you guys had any tips or things I will
> find out I need half way through.
> I plan on replacing everything except the cat, manifold and on.
>
> I've been reading and it sounds like manifold cracking is a fairly
> common symptom for older cars (I just passed 170k).
> From what I've read, I should be on the lookout for an 8v dual pipe
> manifold? What year range will fit? Can I get this new/order from
> somewhere or do I need to spend some time in a junkyard?

The single outlet/toilet bowl manifold has a tendency to crack, the dual
manifold is pretty solid. All 8V A2 (85-92) dual outlet manifolds are
the same. The Corrado G60 (all years) is slightly different but is
completely interchangable. Gaskets are the same on all models.

The dual downpipe is the same on all the cars that have the dual manifold as
well as all 16V A2 (87-92) cars (not sure about the 16V Passats or
Sciroccos). The dual downpipe however features the flex coupler which tends
to have its own issues. If you go with the dual manifold you have to use
the dual downpipe.

The Corrado G60 downpipe is very similar to the naturally aspirated dual
downpipe, but the flange to the cat is different. I believe you should be
able to make it work, but you will need to make sure you get the gasket
for the Corrado G60. The Corrado flange is like a big slab of metal thats
welded in place. The gasket is similar to a standard exhaust manifold
gasket, whereas the NA version is like a floating coupler which uses a
metal doughnut. I suspect the Corrado version is a better design but
its a little harder to work with.

One other thing to be aware of. I'm not sure where the O2 sensor on your
car is located, but the dual downpipe/manifold do not have O2 sensor bungs.
The O2 sensor bung is located in the cat. If yours is in the manifold this
will present an issue for you. If yours is a 91, I'd suspect its in the cat,
but then I'd also suspect you already have the dual exhaust setup.

A rattling exhaust is usually just a sign that its misaligned. You can often
just go under the car and tweak a few things, replace the hangers, etc, and
the noise will be gone.

Speaking of hangers... There are two types, the regular ones, and the chain
style. The chain style are better (its a rubber coated chain), but they are
more expensive, harder to find, and significantly harder to install. But they
also don't break and have your exhaust fall off on you. Its something you
may want to think about before replacing the exhaust.

Another thing to think about is if you just want to buy a catback system like
a Techtonics or Eurosport, or something similar. Its cheap, decent quality,
and all the pipes and muffler are all set up for you, it just slips together.

My O2 sensor is certainly not in the cat, I replaced it a few years
back; I remember reaching pretty far, so it's either in the downpipe
or the manifold. I currently have the single pipe manifold, with the c-
clips. I've recently replaced one of the clips after it snapped on me
midway through a 400mi drive. I've been doing some pricing and it
looks like I can do the whole exhaust system for ~$600 from
techtonics. This system eliminates the first muffler so will the
exhaust be louder or will the volume remain the same? I'm not too keen
on having a louder/flashier exhaust, but if i'm going to spend the
time replacing it, i'd much rather spend a few extra bucks and have
more fun with my car in the end.

I just checked out the engine today, is the easiest way to approach
removal of the exhaust manifold from above? So I'd need to take off
the intake manifold, fuel injectors (cleaned out the injectors a year
or two ago and they all had a nice spray), fuel rail... is the
anything I should think about replacing/cleaning while i'm in there?

-Matt

Spray some rust penetrant on those exhaust manifold nuts over the next XX
days. They are the worse part of the job.
Yes I usually do them the same way you are..........from the top.
If you need some heat for those nuts.....and you don't have the big torch
maybe:
MAPP gas torch
or maybe even a Heat Gun might work. It will take longer, but I have used
one successfully for other rusted bolts/nuts.

I think if you eliminate one of the mufflers = more noise and you might not
be happy. :-(

Three wire 02 sensor can be put onto the cat, or right before it if needed.
;-)

"mini chifa" > wrote in message
...
> My O2 sensor is certainly not in the cat, I replaced it a few years
> back; I remember reaching pretty far, so it's either in the downpipe
> or the manifold. I currently have the single pipe manifold, with the c-
> clips. I've recently replaced one of the clips after it snapped on me
> midway through a 400mi drive. I've been doing some pricing and it
> looks like I can do the whole exhaust system for ~$600 from
> techtonics. This system eliminates the first muffler so will the
> exhaust be louder or will the volume remain the same? I'm not too keen
> on having a louder/flashier exhaust, but if i'm going to spend the
> time replacing it, i'd much rather spend a few extra bucks and have
> more fun with my car in the end.
>
> I just checked out the engine today, is the easiest way to approach
> removal of the exhaust manifold from above? So I'd need to take off
> the intake manifold, fuel injectors (cleaned out the injectors a year
> or two ago and they all had a nice spray), fuel rail... is the
> anything I should think about replacing/cleaning while i'm in there?
>
> -Matt

mini chifa > wrote:
> My O2 sensor is certainly not in the cat, I replaced it a few years
> back; I remember reaching pretty far, so it's either in the downpipe
> or the manifold. I currently have the single pipe manifold, with the c-
> clips. I've recently replaced one of the clips after it snapped on me
> midway through a 400mi drive. I've been doing some pricing and it
> looks like I can do the whole exhaust system for ~$600 from
> techtonics. This system eliminates the first muffler so will the
> exhaust be louder or will the volume remain the same? I'm not too keen
> on having a louder/flashier exhaust, but if i'm going to spend the
> time replacing it, i'd much rather spend a few extra bucks and have
> more fun with my car in the end.
>
> I just checked out the engine today, is the easiest way to approach
> removal of the exhaust manifold from above? So I'd need to take off
> the intake manifold, fuel injectors (cleaned out the injectors a year
> or two ago and they all had a nice spray), fuel rail... is the
> anything I should think about replacing/cleaning while i'm in there?

I'd disconnect the downpipe from the manifold and then get the manifold off
from below. I haven't done it in a long time, but I don't think its
neccessary to take the intake manifold off, but maybe my memory is fuzzy.
And I've never actually worked on the toiletbowl manifold.....

As for the Techtonic exhaust, $600 seems very steep. Their basic alumnized
exhausts are in the range of $2-300 and are very easy to install. I wouldn't
mess with getting an aftermarket manifold/downpipe because they should be
available dirt cheap used (even the dual manifold/downpipe, which is pretty
darn good). I think the catback is a bargain if you are looking for a simple
quick replacement for the entire exhaust. The exhaust is not in anyway
flashy (it just looks like a standard exhaust but all the pipes are a little
bigger -- 2.25" maybe?). It is louder, but its not fart can/ricer kid
louder. You can add an extra resonator (factory option) if you are really
concerned about noise. Eurosport is also another alternative, I had one of
them for a while, I think its quieter than Techtonics. With out any other
mods, I wouldn't expect an aftermarket exhaust to gain you much, but the
combination of it and the dual manifold/downpipe might give you a 5% power
boost.

Checkout www.thescirocco.com if you are looking for good prices on Techtonics
stuff

A few last things:
I spoke with a guy from a local vw auto store, T Hoff. He seemed to
think that since I had a 4door, not a 2door, golf that I would have
trouble with things lining up correctly lengthwise.

My exhaust currently has a 2" cat, will I be able to use it with a
dual downpipe? Also, the catback from techtonics that I'm looking at
is #253.410. It says will fit 50mm (~2") but it is a 2.25" pipe, is
this a non-issue?

If you have time, how do these look?
http://cgi.ebay.com/ebaymotors/_Car-...m230264178322&
http://cgi.ebay.com/ebaymotors/_Car-...cmdZVie wItem

you've all been a big help,
-Matt

"mini chifa" > wrote in message
...
> Hi all,
> I have a 91 golf gl 8v. The exhuast has at least one leak, a shot
> muffler, and annoying rattle that has finally gotten the better of me;
> so i'm replacing it this summer. I'm going to start ordering parts
> soon and I'd like to know if you guys had any tips or things I will
> find out I need half way through.
> I plan on replacing everything except the cat, manifold and on.
>
> I've been reading and it sounds like manifold cracking is a fairly
> common symptom for older cars (I just passed 170k).
> From what I've read, I should be on the lookout for an 8v dual pipe
> manifold? What year range will fit? Can I get this new/order from
> somewhere or do I need to spend some time in a junkyard?
>
> --- The manifold is the same from 85-92. The 85-92 dual outlet manifold
> pipe is over $200. The 3 piece exhaust system from the converter back is
> $150. The converters are different for dual or single downpipes. And is
> about $150 for dual, And $200 for single. If you find the stores are a
> lot more then this. Parts place for VWs will have what you need. They are
> a new and used VW junkyard. With more parts then all the online vw stores
> combined. They do however have bad customer service.If they screw up your
> order. They may have a manifold too. Or a used downpipe. I find their
> exhaust systems are high quality and priced better then others.
> 1-248-373-2300