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Date:         Fri, 29 Jun 2007 19:17:59 -0400
Reply-To:     craig cowan <phishman068@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         craig cowan <phishman068@GMAIL.COM>
Subject:      exaust removal
Content-Type: text/plain; charset=ISO-8859-1; format=flowed

I have installed a new muffler and tailpipe with new gaskets, but to no avail, as i still have a gaping leak at the #1 cylinder head. The gasket flaked off partially and has started it seems (as indicated by my mechanics) to erode the engine head. They feel that in order to replace said gasket, they will have to file down the head to get a flat surface but are concerned and perplexed by the idea of doing so without breaking any of the exaust manifolds. They believe that the pipes will have to be split at every joint they connect at in order to replace the exaust and that i'm opening up a few interesting issues involving rust.

Is there a prefered method of removing a single exaust manifold port (or a single side) far enough to get a file in there and file the head slightly without having to remove the head studs and without having to break the entire exaust system. They told me it could be as much as 4 hours of work ($75/hr!!!!).

I sudgested the idea of getting a seperate complete exaust system, cutting the bolts with it out of the car and replacing them and the gaskets as needed to make the mechanics job much easier. Is this a good idea? If so.....whos got a spare 1.9L exaust system they wish to part with?

-Craig '85GL


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