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THS Exhaust Manifold -ever fitted one ?

Discussion in 'A4/S4 forum(B5 Chassis)' started by andysAko4, Aug 23, 2009.

  1. andysAko4
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    andysAko4 Member

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    [Aug 23, 2009]
    Jst got my new manifold and tired fitting it yesterday.Ok up to putting nuts back on along the top and :wtf: no room the put the nuts on !!.After alittle :keule:got some on but unable to tighten up. Any ideas any one pls:sos:
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  3. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    I removed the studs from the head and used socket head cap screws(m8 x 40 iirc ) and installed most of them into the mani before attempting to fit it. I then used a long ball ended 6mm allen key with additional lever handle to get them tight
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  4. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    The only problem with that is that your torqueing the bolts up against an alloy head...

    Your at more of a risk of ripping the threads out the head than using studs.

    I suspect you'll need to modify some spanners or something to get into them.
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  5. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    Will not get a spanner in there, i tried all sorts 1/4 dr sockets are too big even. Using the allen bolts is a common mod but as stated care must be taken. It why the length is important, any longer bottoms out, and any shorter may strip the threads
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  6. ian52
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    ian52 2000 a4 1.8tqs-yellow

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    [Aug 23, 2009]
    surely that is very bad design if you cant bolt it on properly?
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  7. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    Seems to be par for the course in the cast K03/4 manis
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  8. andysAko4
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    andysAko4 Member

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    [Aug 23, 2009]
    Thks Mark,a fountain of knowlwedge,what would we do without you :respekt: ....Did you use the washers with the bolts when fitting? I was expecting to have to make a tool or socket.:think:
    I have pm THS about this. I’ll post their reply when I get it.
    Should be interesting.
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  9. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    I used the Thick washers i think as the first lot of bolts i had were slightly longer so i used the thick washers, i have got pics somewhere......
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  10. Broken Byzan
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  11. jcb
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    jcb Active Member VCDS Map User

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    [Aug 23, 2009]
    goose neck open ended spanner
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  12. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Aug 23, 2009]
    it works on the top nuts, not on those damned lower ones..... GGGRRRR
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  13. andysAko4
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    andysAko4 Member

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    [Aug 27, 2009]
    This is reply I got from THS , Not sure about filing though LOLl

    It should be possible to fit without removal of the head. You may find it easier to use a spanner rather than a socket on some of the nuts. Are you sure that the manifold is located true on the head. We had one customer mention that the top of the manifold flange just came into contact with the top of the head casting and he had to file a small piece of the top of the manifold.

    Hope this helps
    #12

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