RS2 Exhaust Manifold Removal

[steverrquattro]

Up until recently I had no idea that the RS2 exhaust manifold was prone to cracking. Since inspecting mine a have a few small hairline cracks and I'm considering removing it for repair.

The dilema is that even after soaking in penetrating oil, there are several nuts which seem VERY tight, whereas some were actually loose?

1. What is the best method of removal re. the VERY tight nuts?

2. Is the EM relatively easy to weld?

3. Should I throw it in the bin and get a new one and if so which type - using RS2 turbo.

Thanks in advance.

[Costash]

When I took mine out I put some w40 on the ex mani nuts and left them to soak and after it was easy to undo them.You gonna need some patience when you gonna start removing the botom ones which are a pain and you need a special bend spanner. About cracks depends where they are located .I have cracks on the colector but It is not leaking and no point to weld them.Don t know how bad yours are.Mine were looking like that.

[veneto rs2]

Tried myself to weld but with no avail.

If you go for a change go for Wagner (original) it's not cheap but it defenetely worth the money.

Stefano

[jsws3]

Up until recently I had no idea that the RS2 exhaust manifold was prone to cracking. Since inspecting mine a have a few small hairline cracks and I'm considering removing it for repair.

The dilema is that even after soaking in penetrating oil, there are several nuts which seem VERY tight, whereas some were actually loose?

1. What is the best method of removal re. the VERY tight nuts?

2. Is the EM relatively easy to weld?

3. Should I throw it in the bin and get a new one and if so which type - using RS2 turbo.

Thanks in advance.

If you would like to keep the original 20v rr manifold my friend has a 20v head with manifold and turbo taken off a car 12 + years ago he will sell if your interested there are no cracks in it .

[driftin jo]

In all seriousness unless the cracks are really bad just forget about them, they are not likely to get worse in my experience. I've had cracks on all my Audi turbo cars over the years and put hem back together and 50k miles later they are just the same. I'm not saying there is not the occasional one that lets go but I think it is very rare.

If you do decide to weld it use a tig with inconel rod, you also need to get the manifold nice and hot before you weld it so as not to end up with localised heating when you weld as this can worsen / cause other cracks. You really need to give it to a professional tig welder but if your local welder does not have ant inconel rod I could (borrow you some ) from work as the minimum order price would make you **** the bed.

[newsh]

Softly softly.. Sometimes the studs break. Welding will probably not last. The Wagner RS2 evo manifiold is an excellent choice, it's also designed to be easier to fit, with more clearance around the studs to get the spanner in