Help: What order to assemble 1.6TD manifolds?

[rumbling_caddy]

  So I finally got around to bolt on 1.6td external parts to my 1.6 NA then I got stuck.  The heat exchanger and related coolant hoses went on fine.   Next I replaced the NA oil pan with the TD one which has the turbo oil return fitting.  After that I assembled the exhaust manifold with the turbo manifold and down pipe into one unit.  Then I bolted that entire unit to the block,  but now I can't get the intake manifold on because there isn't enough room for tools, etc.

Does the intake manifold have to go on first and I have to take the turbo assembly apart again?  Perhaps I can just unbolt the turbo manifold from the exhaust manifold?  What's the best way to assemble these 1.6td manifolds?

[mystery3]

You need smaller hands. Really you should be able to get the intake on with just a massive amount of patience a few scraped knuckles/hands and a sore back/legs/arms. It's extraordinarily tedious.

[theman53]

I had to take mine off the manifold. I could get all the nuts except the one by the oil drain.

[rumbling_caddy]

  Thansk guys.  Anymore tips or tricks?

  Oh, I forgot to mention the engine is still in my caddy so getting to the bottom nuts on the exhaust manifold was tough enough the first time.  Well looks like I have to take it apart again unless there a good trick to to install the intake manifold with just an allen wrench or something

[R.O.R-2.0]

usually when im working on a mk1 rig, i do all the exhaust work from the bottom. i take off 6 from under neath, and the 2 top outside ones from the top. it goes alot easier that way, if you try removing the stuff from up top, you need like 3 elbows on your arm to get it to bend the right way.

[rumbling_caddy]

usually when im working on a mk1 rig, i do all the exhaust work from the bottom. i take off 6 from under neath, and the 2 top outside ones from the top. it goes alot easier that way, if you try removing the stuff from up top, you need like 3 elbows on your arm to get it to bend the right way.

   That's how I got the nuts on the bottom on the exhaust manifold the first time, laying on my back.  Just got a bit frustrated yesterday after spending hours on wrenching before getting stuck.  When I took the 1.6 NA manifolds off, the intake came off 1st then the exhaust one 2nd.  Probably that's why I though I should be able the reverse the procedure to reassemble even though the 1.6 TD manifolds are different.  Oh well, live and learn!

  The two C-springs hold the downpipe to the toilet bowl flange look like it's going to be tough to get on too.  I saw some pics of using a U-bolts with extra nuts to open them up.   Is that the best way to get those on?

[smutts]

Is that the best way to get those on?

Depends how much you value your fingers, I have a "proper" tool, and it still is an utter swine to use on the turbo-diesel. But that said, it's a crap design to dismantle, reassemble, but has never leaked. Too many other cars have been a total git with leaking exhaust joints at this point that I forgive it. 

If you don't have a 3/8" drive socket set for this job, then there is no hope, a variety of weird shape spanners help too.

[rumbling_caddy]

   Ok so I took the turbo assembly off and installed the intake manifold first.   Next the down pipe had to be removed before the turbo w/ exhaust manifold attached would go past the firewall.  Now I was thinking everything would go fine but noooo...  One of the exhaust manifold stud is almost totally obscure by the turbo.  I can barely feel the tip of that stud so it seems almost impossible to get a nut on there.  Perhaps somebody slender hands and long fingers and a piece of gum could do it, but then how would that nut be tightened?

Looks like I have to separate the turbo and the exhaust manifold and try again ...

[theman53]

I had to take mine off the manifold. I could get all the nuts except the one by the oil drain.

Looks like I have to separate the turbo and the exhaust manifold and try again ...

yep.

[rumbling_caddy]

  If some body else is bolting on 1.6TD parts to a 1.6NA don't forget that there's a heat shield that must be installed along with the intake manifold.



The order that worked for me is something like this.  It's tricky, one piece at a time has to assemble mostly from the bottom side.  Much easier with the engine outside the car I suppose.

  1) Intake manifold w/ heat shield
  2) Exhaust manifold by itself (reach bottom nuts from the underneath)
  3) Turbo (tighten the four 12mm bolt from the underneath.  Two are kinda hard to get to)
  4) Down pipe bracket
  5) Down pipe

All assembled

[rumbling_caddy]

  Does the 1.6TD down pipe sits a little further back than the 1.6NA one?  Anybody knows for sure?

With the stock caddy exhaust setup I had to remove the heat shield on the section with the toilet bowl flange.  Even after that that section is touching the steering rack mount causing engine vibrations to transmit into the interior.  It's pretty bad.  Tomorow I will loosen the down pipe bolts and it's bracket and see if I can move the exhaust pipes toward the front so it's not touching anymore