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Exhaust manifold and turbo removal |
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The Transporter 
Vanorak 
Joined: 08 Nov 05 Status: Offline Points: 1012 |
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 Posted: 11 Apr 12 at 21:07 |
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My manifold was pretty knackered, cracks on most of the flanges and the turbo flange fell off... I doubted that it could be welded up but the chap did a cracking good job of it .... He recons that the manifold is some kind of stainless steel fabricated in a mud hut in the third world.
Tip to removing the manifold is to remove the rear engine mount.... It really does make life easier... I did mine on the drive in the rain and was a doddle to do......That is when you compare it to changing the DMF..  |
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2004 174bhp AXE engine..... Belligerence has been confirmed.
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CMP260
Groupie 
Joined: 02 Mar 12 Location: wales Status: Offline Points: 170 |
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Posted: 21 Apr 12 at 18:28 |
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I got my T5 Turbo out, but cant get it back in.
 Will removing the rear engine mount help? Will I be able to push engine forwards to gain space or what?is removing rear mount quick easy job? ta
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was a 2006 130 shuttle
now a 2006 174 multivan |
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fantasam
Groupie
Joined: 12 Dec 09 Location: Luxembourg Status: Offline Points: 162 |
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Posted: 22 Apr 12 at 09:17 |
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Very easy and will definitely help. The access to the turbo from below is much better with the mount out of the way.
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Man of few words, many farts
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SwindonT5
Not Quite Newbie 
Joined: 17 Nov 12 Status: Offline Points: 15 |
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Posted: 17 Nov 12 at 16:47 |
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I have made a start on my AXE today, I have all the copper nuts and washers off the manifold apart from the lower second one in from the drivers side, I am off to purchase a 12mm ratchet ring spanner tonight.
Mine let go yesterday after rasping for a couple of years, turbo packed up and it ran rough, yet to discover what it is though Could they have made the manifold any harder to get to? |
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max and caddy
Vanorak
Joined: 12 Dec 09 Location: Lancaster..uk Status: Offline Points: 4866 |
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Posted: 17 Nov 12 at 17:16 |
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SwindonT5
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Joined: 17 Nov 12 Status: Offline Points: 15 |
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Posted: 17 Nov 12 at 18:43 |
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does anyone know if the manifold will come out with the turbo in place, it doesn't look like it will?
Shame I like Crafters too, hired one a few years back |
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 17 Nov 12 at 20:03 |
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No, not enough room unless you unbolt the turbo and lay it back. Then you will need a new turbo-to- block crushable gasket so you might as well take it right off and give it a good check over.
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2004 2.5 174
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SwindonT5
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Posted: 18 Nov 12 at 09:49 |
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cheers will do, just got it up in the air!
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T5 173 Caravelle
D3 TDV6 Discovery A6 Avant 2.0D Polo 1.2 3CYL |
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 18 Nov 12 at 10:35 |
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Good luck.
Make sure nothing can can fall into any of the turbo hoses unnoticed...
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2004 2.5 174
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SwindonT5
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Joined: 17 Nov 12 Status: Offline Points: 15 |
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Posted: 18 Nov 12 at 10:48 |
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OK its big question time. I think I might be off the mark with the Manifold/Turbo, as so far I have not found any soot signs of leakage, I was hoping to find something when it came off. However when I got underneath it today to start on the engine mount, I spotted a very oily patch on the near side front by the radiator. A quick glance with the torch and the source of the leak is a huge hosepipe blown off the intercooler, this is the pipe that goes from the EGR down to the cooler, MY EGR is very oily too and I suspect that the oil has made its way down the pipe and lubricated enough for it to blow off.
No wonder I couldn't feel any exhaust fumes blowing round the manifold.  So my question is this, with this pipe off would that cause my symptoms, lack of power and fumes in the engine bay? this is how clean my manifold is |
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T5 173 Caravelle
D3 TDV6 Discovery A6 Avant 2.0D Polo 1.2 3CYL |
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SwindonT5
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Joined: 17 Nov 12 Status: Offline Points: 15 |
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Posted: 18 Nov 12 at 10:53 |
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MAnifold
 Pipe Off  |
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T5 173 Caravelle
D3 TDV6 Discovery A6 Avant 2.0D Polo 1.2 3CYL |
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energysolutions
Vanorak
Joined: 02 Dec 08 Location: Earth (For Now) Status: Offline Points: 3684 |
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Posted: 18 Nov 12 at 12:50 |
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Yep, that would be the source of your problems I would imagine - the tabs that hold the hoses together wear and one will fail which causes a leak (usually accompanied by a strange noise) this, in turn, puts more pressure on the remaining tab and eventually it fails and the hose blows off dumping all the exhaust fumes into the engine bay
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!!Never Eat Yellow Snow!!
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 18 Nov 12 at 14:43 |
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Yep that's it. You normally hear them go with a loud pop followed by smoking/knocking and almost no performance.
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2004 2.5 174
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SwindonT5
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Joined: 17 Nov 12 Status: Offline Points: 15 |
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Posted: 18 Nov 12 at 16:03 |
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Yippe Skippy!!!
I removed the pipes and cleaned them up, all fitted back together nice and tight. Went for a test drive and it blew off again after a few hundred yards!! So I started looking for the worm off tabs as described above and found this  I am trying not to think of how long it has taken me to get to this simple stage, but I am putting it all down to experience and finally getting to grips with my T5. All in all I found it very nice to work on, and I am surprised at how quick I can remove and re attach the air cleaner and all the pipes. I am just grateful that it didnt blow off when I was in the Alps this summer!  is this pipe main dealer only or is there an online trader I can order one from I will have a VW commercial Dealer 1 mile from home next summer but at the moment it is a 70 mile round trip! Also I need to fix the oil in these pipes, the small flexible metal tube from the centre of the manifold is nice and dry but the big fat turbo cooler pipes are full of oil, its using about a litre for every 4000 miles. is this oil coming past the piston rings or could the turbo be leaking oil inside it self? Edited by SwindonT5 - 18 Nov 12 at 16:17 |
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T5 173 Caravelle
D3 TDV6 Discovery A6 Avant 2.0D Polo 1.2 3CYL |
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 18 Nov 12 at 17:52 |
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Some people here have drilled and fixed them with a self tapper. New hoses aren't cheap and there is no guarantee it won't happen again. They did go over to a version with jubilee clips later but that blew off too!
A coating of oil in the hoses is ok but if there are puddles of it then it it does sound like the turbo seals. If there is loads you should clean out the intercooler as well.
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2004 2.5 174
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john the sparky
Yardie 
Joined: 26 Oct 10 Location: Bucks Status: Offline Points: 574 |
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Posted: 18 Nov 12 at 19:41 |
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is yours a 1.9tdi?
this is supposed to be a real common fault on them, and happened on my altea, refitted pipe, and it blew off.... (like you) replaced pipe and clip and it did it a bit later so I had read about the self tappers, so did that... there was wear to the intercooler coupler as well on mine, so I put 4 tec screws around the pipe.... and job jobbed! hope you get it sorted, and pipe for altea was about £38 from tps IIRC (was suprised how resonable it was)
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Jez211
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Joined: 20 Oct 18 Location: Scotland Status: Offline Points: 1 |
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Posted: 20 Oct 18 at 00:24 |
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Hi Folks, am I missing something here with regard sourcing a manifold?
I have a t5 130 with the exact symptoms you all describe, low on power, limp mode on hills, fumes in cab etc. I investigated and found I had a rather large crack on the manifold which is sending fumes toward the Air box. I ordered a £60 replacement manifold with all the gadgets and a 5 year warranty from fleabay as vw wanted £470 plus £98 for gasket set. SO, I havnt heard anything on tested after market manifolds mentioned on this thread but my reckoning is I fit it, if it lasts 5 years great, if not I get them to send another. I can handle a couple of hours Labour on a weekend. |
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T5 TDI
Vanorak
Joined: 05 Nov 05 Status: Offline Points: 3687 |
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Posted: 20 Oct 18 at 09:24 |
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I've had one on mine for 3 or 4 years now with no problems. The price has come right down now. You won't be fitting it in a couple of hours though!
 You have to take the turbo off to get the manifold off. If you take the rear engine mounting off you will have much more room because much of the time you will be working underneath at arms length. Soak all the manifold nuts in Plus Gas the day before because if any break (and it often happens) you will need a specialist to drill them out. Replace all the nuts. The only complaint I have heard is on the 174's there is almost no clearance to get the turbo in even with the manifold loose. Darkside Developements make a mention of grinding a small bit off the manifold on their website but I managed ok. It's not a fun job though! http://www.brick-yard.co.uk/forum/topic89140_post697390.html#697390
Edited by T5 TDI - 20 Oct 18 at 09:26 |
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2004 2.5 174
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SwindonT5 wrote: