1.8T exhaust manifold crack + turbo crack?

[theadventureneverends]

I was hearing a small exhaust leak on startup and found this crack in exhaust manifold last night. Not the most common conversion but hoping someone here has some input. I can definitely feel exhaust on my finger when engine is cold near crack. Not sure if goes away once warm. We are trying to use the westy once a week right now and had a small trip planned this weekend. Probably risk damage if continue to drive until new manifold comes in?

I am not looking to have the crack welded I will be replacing. It looks like several companies make aftermarket high flow exhaust manifolds for the 1.8t. Mine is 2005 Jetta AWP done by SAH.

Anyone have experience with the aftermarket ones? Any suggestions on purchasing a new manifold. Just off phone with VW dealer, parts department list new is $535 for manifold.

[Pcforno]

I would be very cautious with the “high flow” exhausts for your particular application. Hi flow manifolds typically increase flow above 4500 RPMs which you shouldn’t hit with your transaxle anyway. Your OEM manifold is designed to be restrictive to the extent to minimize low to mid end turbo lag at the expense of high flow at high RPMs. Most 1.8t enthusiasts don’t report much gains even on the top end unless the turbo is flowing more after changing out the tiny K03 for a k04. I’d go for another OEM if I were you. You need the low end torque more than the top end
My .02

[theadventureneverends]

Pcforno appreciate your advice! Not necessarily looking for more power. Looking for a quality replacement manifold. Just got off the phone with VW looks like I can get a possibly better stronger manifold for about $100-200 less from aftermarket companies. List at VW is $535. I am seeing aftermarket via google search for about $300. Sure appreciate keeping things oem though. I am completely ignorant with the add-ons aftermarket for the 1.8T. I just do not know if I am better off with an aftermarket for $300 or oem for $535?

[Pcforno]

Not sure which manifolds you’re referring to - most aftermarket ones are for higher flow, and some don’t last if you read the Audi and VW forums. For my money I’d go OEM

[Christopher Schimke]

I completely agree with Pc here. "Better" is a relative term. The bigger, longer aftermarket manifolds tend to kill low end power, and low end power is exactly what you need with a Vanagon. In addition, they tend not to last as long as the factory manifolds. So while "better" may equate to cheaper and possibly more top end power, it's definitely not better for drivability in a Vanagon and not for longevity.
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[theadventureneverends]

Appreciate the advice looks like it will be OEM. Any suggestions as other options besides $535 from dealer?

Thank you!

[vanagonjr]

[theadventureneverends]

John, thank you for that suggestion. Never heard of them just checked their website and will be calling in the am!

[SyncroJack]

Would this one fit? On sale too

https://www.ecstuning.com/b-genuine-volkswagen-audi-parts/exhaust-manifold/06a253033al/

Or try a pick n pull if you wanted a used one?
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86 Syncro 1.8T power!, 76 Westy

[Pcforno]

Yes! That’s a great deal. Just beware as ECS is widely known as “extra cost shipping”

[robbiecanter]

I love ecs, never had a problem with them at all.
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[jberger]

Why not weld that manifold? I ran into this with my Mk2 8v jetta. The manifold was cracked and a replacement was not available. Drilled out the ends of the crack, Vee'd it out real good and welded with the appropriate high nickel cast iron SMAW electrode. Still tight after a year. And it was a doozy of a crack.

J

[Zeitgeist 13]

Yeah, I'll bet Zeigler's here in Oly would weld that for you

http://www.zeiglerswelding.com/
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[theadventureneverends]

Removed exhaust manifold sure was hoping not to have to remove turbo but one manifold nut just couldn't be reached with the turbo in place. What could have been quick took a while. The crack is significant in the manifold and for $300 just seems to make sense to purchase new oem rather than try to have welded, I do appreciate the suggestion though and if one wasn't readily available I would give it a try.

I was expecting to disassemble today make a parts list and order tomorrow. I was able to disconnect 2/3rds of turbo and move just enough to get to the last manifold nut which was better than removing the whole unit. But the bummer now is looking down into where the manifold dumps into turbo I am seeing what is a crack. Briefly reading on Google sounds like some cracks in there are normal as long as not leaking. So now probably end up removing to inspect better.

Anyone have suggestions for a 1.8t forum where I can post a pic and get advice from folks who are familiar with these turbos?



Thank you.
John

Crack in Turbo?

[theadventureneverends]

Texted with Stephan from SAH this am and the crack in the turbo is nothing to be concerned about. 7 years after conversion he takes time to respond to questions happily! Highly recommend Stephan's Auto Haus.

Ordered new oem manifold from ECS today $290 and several other pieces of hardware and gaskets.

Appreciate all the advice thank you!

[vanagonjr]