Do I have to remove head to install turbo, intake, and exhaust manifolds?

[mtnbob]

Just wondering if there was an easier way
Getting ready to to a turbo changeover. Hope I don't need a different rear engine mount

[Quantum TD]

No, you don't need to remove the head. But, you do need to have a good 6mm allen-bit socket, and lots of patience. Rubber arms help too.

Basically, you'll need to remove the intake manifold. I usually feel in there with the tip of the allen bit, find a bolt hole, and hammer the thing in there (to prevent stripping). Then loosen each one.

Once the intake's off, have fun with those exhaust nuts! Aerokroil or PB blaster them overnight. Use heat if necessary.


Whenever I do a motor swap or a head job on a MK1 or MK2, I always leave the intake and exhaust manifold off until the motor (or head) is in the car. Then I give the head a reach-around and install the manifolds.

[mtnbob]

Thanks for the advice. I'd prefer to avoid replacing the headgasket and bolts if I dont have to. I couldn't even find the bolts to remove the intake manifold today, but I'll have a better look at it tommorrow in sunlight.

[burn_your_money]

There are 6 intake manifold bolts. If you look at your turbo intake you will see exactly where they will be. You will need shorter bolts for the turbo intake... or maybe longer, I forget now.

[smutts]

 ;DYup, it is a right git of a job!
If I was doing it again I would be tempted to jack the engine and remove the front engine mount (it will probably be knackered anyway) and ease the jack down, the engine should flop forward enough to make it  merely a wretched job to get at all the bits at the back. But I don't know wether this would work, or instead the engine falls out onto your legs , so best have a think first. The turbo manifold  is a 2 foot thick casting of recycled depleted uranium, at least that is how it feels with the head attached. It is heavy.

[mtnbob]

My only alternative would be to remove the head, then replace the headgasket and bolts? Is that any easier? I guess If I go that route, do the timing belt too since I have to switch in a turbo injection pump Any other suggestions? This is the biggest undertaking I've attempted so far.

[jettabrendan]

Not gunna lie, your probably going to have to replace the headgasket at some point, so I would just take off everything, change to studs, new gp's and block heater while its all apart.there isn't much space to work with and if you don't have a hoist it sucks getting under them, and I'm not a big guy. Just my 2 cents...

[burn_your_money]

Personally out of every task that I have ever done on a VW diesel, doing a head gasket job is BY FAR my least favorite. Unless you suspect a problem with your gasket I wouldn't touch it. It's not that hard to get the turbo/manifolds off. Your back will hate you the next day though, I can promise you that.

[jettabrendan]

Really haha, I liked doing it, I would do it again any day. To each his own I guess.

[smutts]

It's not THAT hard to do the manifolds, but it's just a fiddle as it is tight to the bulkhead (firewall?). Try the engine mount idea, there may be some joy there.

[88jetta350]

If you do go that route, please let us all know how it works for you, so we know if we should do it that way ourselves from now on.

[Jettage1]

Really haha, I liked doing it, I would do it again any day. To each his own I guess.

Stop by next time you're in my neck of the woods - got one all ready and waiting just for you!   

[macka]

Really haha, I liked doing it, I would do it again any day. To each his own I guess.

Stop by next time you're in my neck of the woods - got one all ready and waiting just for you!   

he has to stop at my place first

[fatmobile]

Setting the head on with the manifolds attached won't be easy either. Probably a 2-person job.

[SolarSteve]

Placing the head on with the manifolds on isn't very bad at all IF you take 2 of your old head bolts and cut them off about 2 - 3 inches from the bottom and then grind a slot in the top to fit a screw driver.  Once you are ready to install the head, screw the two bolts into two head bolt holes at adjecnt corners, set the gasket on the block over the studs and lower the head down over the studs on to the block/gasket.  Install the first 4 new bolts finger tight and then use a long skinny screw drive to unthread the cut bolts.  Use a stick magnet to pull the cut studs out and then press on with the install.

Or just install head studs...