96 GTI Toned Pipe Assembly Loose/Pinhole Leak

[Rock Creek Rider]

96 GTI running stong again after cleaning out carbs and replacing gray fuel line thanks to advice from this forum! THANKS GUYS

This weekend during all the heavy 4th boating traffic, the 3 bolts/1 nut holding the toned pipe assembly had all vibrated loose off the exhaust manifold!

After bolting and torquing it back down all seems to be well with the exception i noticed a pinhole size leak in the metal area betweek the top 90 degree elbow fitting and the lower elbow fitting - right in the middle where there is a circular weld.

Questions: (1) Are there issues that I need to be aware of that caused the toned pipe assembly bolts to vibrate off the manifold? (2) Can I just patch the pinhole leak in the tuned pipe? Was internal rust the culprit here?

 

[Woodstockaz]

Same problem. It's a bunch of bull if you ask e. Bad design. That pipe is $600!!!!! Buddy is welding it for free so I'd look into that too.....

 

[kustomkarl]

You can get it welded, or scuff it good and use either jb weld or a 2 part epoxy to repair it.

Karl

 

[Rock Creek Rider]

Thanks Karl. Seen a lot of post also about the manifolds bolts breaking which I have now encountered for first time. Ski's been in storage for 8 of the past 10 years so the hours are insanely low.

I've checked the motor mounts and all seem to be in excellent condition. No cracks, minimal engine movement, no spinning mounting bolts.

My plan of attack is to replace the exhaust manifold bolts holding on tuned purple pipe with 3/8 stainless, retap manifold to accomidate, loctite blue, and tourque to factory specs.

Do you think this will resolve the issue or is there a specific cause that I have not considered other than "bad design" as I see noted in many post?

 

[kustomkarl]

You should be fine after this...keep your fingers crossed.:ack:

Karl

 

[JPX]

It's just not that great of a design.

Check the rubber isolators - two of them - on the side of the engine where the next section of exhaust pipe mounts. If they are blown, then there is slack at the bolts and the vibration of the motor directly transfers to the second section of the exhaust (which in turn vibrates the first section at the manifold a lot more).

Loctite your 3 bolts, 1 nut and you should be back in business. Might want to make it a point to check they are tight before each ride.

I blew a pipe and flooded my boat because of this same exact thing. Your pipe at least is still good (except for the the pinhole leak). Mine cracked in half.:ack:

For the pinhole leak, they guys insist JB weld or similar will hold. I have not tried this myself.

 

[derek]

stainless is hard. stainless cracks instead of giving. you might wanna go grade 8 steel. tougher.

 

[Rock Creek Rider]

:hurray:Thanks guys for advice. Was able to secure a used mainfold with 15mm head bolts/stud versus factory 13mm which i was told was solution to engineering flaw exisiting for years. Loctite blue applied to manifold bolts and torqued to 22 ft lbs. Replaced 40mm long single bolt holding on tuned pipe to manifold with longer 50mm longer bolt and again loctite blue applied. JB weld worked just fine on the pinhole leak. With about 6 hours on ski since repairs, all appears well.

I've seen post where folks have tapped out manifold bolts to 3/8 size which I would beleive would be a great retrofit for this problem also.

 

[kustomkarl]

Glad it worked out for you ...

Karl