manifold help?

[Aaron61191]

basically the problem is my ibiza cupra exhaust is blowing very bad, it seems to be the gasket in the section between the exhaust manifold & the downpipe ( for a start i dont even know the name of this section as im new to this ) two of the bolts at the rear seem to be tightening alright, however the one at the front is just turning & there doesnt seem enough length on the bolt to get a nut on the underside, more bad news, the bolt will not come out as it hits the engine before it can come out.

Hopefully some of you clued up ibiza enthusiasts can fire some advice at me! & not too much abuse for my poor knowledge lol.

 

[rae1001]

Which engine do you have bud? Sounds to me like the threads have stripped from the inside from over tightening.

 

[Cupra137]

Pretty common, happened to mine, had to take the manifold off, get it drilled out and get the turbo threads tapped out to a size up then refit with a larger bolt.
Its tonnes of fun

 

[rae1001]

Haha i bet it is fun. Ive not had a job so little since buying my cupra this dont sound like a cupra though if the dp is coming off the mani so might be easier

 

[Aaron61191]

I may have explained myself not very well, the downpipe isnt joining onto the manifold,there is a section in between (which the turbo is bolted onto) like i said unsure of this part as i dont know much about these motora, i cant check at the moment but pretty sure it says AYP in the engine bay if thats any help guys?

 

[rae1001]

As cupra137 says i think the manifold, turbo etc will have to come off, drilled and tapped then all refitted with new gaskets etc. fiddly job but can be done in a day if you are good with the old spanners

 

[Cupra137]

3 bolts in a triangular pattern going through the mani? They go into the turbo hotside and the gasket between that will be your problem. Its a fiddly manifold off job to get at thr threads below, then tap them out to m12 iirc and get the mani drilled out by a machine shop or yourself to accommodate the larger bolt.
Its annoying but not too much of a hassle

 

[Aaron61191]

Awsome guys thanks for the helpful info im sure il manage when i get some spare time, car is parkerd up for now as it sounds more like a tractor lol, thanks again.

 

[rae1001]

No worries, if you find yourself stuck send over a pm and id be happy to lend a hand if needed

 

[Aaron61191]

so thats the turbo/manifold removed, the mechanic gave me the news i expected that the threads were knakered, however on closer inspection i realise there were cracks in the manifold bolted on to the turbo, as far as i am aware the turbo is fine, but am i right in saying the ko3 turbo has 12 fins & the ko3s has only 8, came across this info online and from what i can see this is actually a ko3s turbo? u guys will know better but my 156bhp ibiza cupra standard should have the k03 right? lol

 

[Cupra137]

Ko3 is std on them yeh, but if its got 8 fins your correct in thinking its a ko3s. Good news there! Most manifolds would have little cracks in them at this age though, aslong as their not huge I wouldn't worry too much

 

[Aaron61191]

thanks for verifying that : definatly good news lol, well it had 3 cracks i could see but thought rather than getting it bored & re threaded then possibly having to replace it eventually anyway id be aswell just going for a new one, will keep this updated though. thanks again

 

[Cupra137]

Good idea. What does your car boost to atm? Should get that ko3s mapped in properly if its not already

 

[Aaron61191]

the guy i bought it from claimed it was running 220bhp and had been mapped, it was boosting to aaround 17psi ? tell me if this is normal or not ! not that clued up on these yet . plans are to get a front mounted intercooler then get it to a garage for a map/ rolling road when the funds are there.

 

[Cupra137]

Get a fmic on it and a good exhaust if not already. 17psi seems a bit low tbh, depends on the map thats on it though. Mine peaks at 21 and holds at 16 and thats revo. Im trying to organise a rr day in Aberdeen at some point so should come along and see what it makes then

 

[rae1001]

Thats good news on the k03s, very rare to find these in standard form nowadays anyway. If you do decide to get a manifold i have a standard manifold lying here. It has one hairline crack but is still very useable. All you would need is the gaskets to go with it and youd be sorted . Send over a pm if interested mate

 

[Aaron61191]

Thanks to both replies lads! Thanks rae i ordered one before i even saw that reply lol, the aberdeen rr sounds good to me

 

[rae1001]

No problems mate. Hope you can make it to the rr day whenever it is, ill come along just for banter if my car aint back on the road, should be though

 

[Cupra137]

I still need to crack on with that, theres no set date so can easy wait til yours is back on the road

 

[rae1001]

Im on holiday now so no reason why it wont be back by end of the month. I guess there will be a bit of a waiting list for a rr day anyway?