Chinafold not fitting

Hello all,

After a harrowing experience removing the old dissolved Aliexpress stainless manifold from the TT Quattro MK1 BAM, I'm having problems fitting the new cast Chinafold. The problem is that after finally getting the collector fitted to the (F23 hybrid) turbo there is no clearance prop to (3") down pipe and the manifold doesn't fit flush with the head. I have read in previous posts that this is not unknown and spacers can be used to correct the problem, the question is will spacers solve the problem, where to start with the spacers & where to get them?

I'm thinking at minimum it will need a head to manifold spacer and may be;

- Turbo - Down pipe?
- Dog bone engine mount?

Also the spacers will make the lower turbo mount redundant, correct?

I'm finding it difficult to understand why it's so far out, the stainless manifold was a pig to install but it went in eventually, this one is way off the mark. I did grind off the tops of the stud hole surounds on the manifold head flange so it clears the head over hang.

The other option is to cut my losses with this configuration and go for a top mounted turbo combo where off the shelf manifold & turbo will be complemented by the custom elements down pipe, tip, turbo lines & charge pipe in my control. This seems like a lot of time & expense just because a manifold doesn't fit correctly and is going to be a last option.

Any help, advice & comments most appreciated.

Collector fitted, stud, nord locks & double nuts

Right hand manifold nuts done up finger tight

Left hand manifold blowing in the wind

No clearance Down pipe & prop

Cheers,

I've already ported it, well opened up the inlet to the same size as the gasket, greatly reduced the 3 spokes in the collector and polished it.

Found out it's the hard line part of the oil feed that stopping the turbo rotating enough, need to change it for hose. I've found the turbo to down pipe spacer\flange on line but where would I get a turbo to manifold spacer if I need one?

Thanks

I've got a solution & a problem;

I've put a 10mm spacer between the down pipe & the exhaust and I've used the flange from the old manifold as a spacer between the new manifold and turbo. I've test fitted it and it's going to work but the old flange is 12mm and I need 17mm, plus 2 gaskets, that's my problem.

I've been around the local (Worthing, West Sussex) metal fabricators and no one can help anyone any Idea here I can get a spacer made up for a reasonable price?

Thanks

Fitted dogbone bushes, brought to light that the engine mounts are shot.

I thought this might be the case but was hopping it wasn't.

Bought these;

https://www.ebay.co.uk/itm/VW-Golf-...e=STRK:MEBIDX:IT&_trksid=p2057872.m2749.l2649

Worked out about an extra £70 over the standard ones for the pair.

Not really surprised they are shot, 18 years old and 117K on the clock.

The new mounts may raise the engine up by 20mm extra above the sub frame, which might change the engine, prop, sub frame & down pipe geometry enough to give the required clearance, have to wait and see.

Hello All,

Update on the exhaust manifold saga, IT'S IN & WORKING.

Ended up with new dog-bone poly bushes, new performance engine mounts (Vibra Technics) and modifying the down pipe.

Order of trail & error;

- Ground out & polished manifold as best I could.
- Made bolt holes in manifold bigger to try making fitting possible (3 turbo holes and head stud holes).
- This enabled it to fit, but the down pipe rubbed against the rear prop shaft.
- Fitted poly dog-bone bushes, hoping to tilt the engine a little thus clearing the rear prop shaft.
- Didn't work.
- Fitted new performance engine mounts, hoping to drop the engine a little thus clearing the rear prop shaft.
- Didn't work.
- Decided to modify the down pipe.
- Did this by using some straight SS pipe a SS 20° mandrel pre-bent section of pipe a smaller SS flexi section & some dodgy welding. I also used a spacer between the turbo and the down pipe (9mm flange from aliexpress).

I put it all together and there was a blow between the manifold & turbo, so I added an extra gasket which made it better but didn't completely cure it, so I added another gasket which has cured it. Not sure how long the 3 (OEM) gasket solution will work, so I have purchased some 2mm copper sheet to make a gasket from if & when the current solution fails.

I've only driven it about 40 miles due to the lockdown and it's going good, still needs a little map tweeking, but that will have to wait until after lockdown.

I've since found out that you can clock the turbo.

If I was doing it again & it didn't fit first time, I would try clocking the turbo before trying anything else, if that doesn't work I would get the turbo to fit to the mainifold & the mounting bracket then modify the down pipe to fit.

You might be lukcy & it fits no problem first time, I think my problems came from both the manifold & turbo being after market items.

If your car is Quattro you might find that the clearance between the prop & the down pipe is a bit tight, this is where the spacer between the turbo & down pipe can help ( https://www.aliexpress.com/item/32712084492.html?spm=a2g0s.9042311.0.0.27424c4dRoYT6X ).

I also got some 3mm manifold to turbo gaskets made up using Micatherm as the OEM steel ones just burnt through, the copper one I made up did work but it wasn't a long term solution;

E Dobson & Co Gaskets Ltd
Unit 1 Holme Mill Ind Estate
Fell Lane
Keighley
BD22 6BN

Tel 01535 607257

PS
I've since changed the turbo for a better hybrid and it went straight in after clocking it a little.