Need help with mk2 exhaust

[Kunu]

Just did the head gasket on an mk2 jetta 8v that I just purchased, and am wondering what the trick is with getting the exhaust clamps ( 2 "c" style stretch clamps that hold the down pipe to the manifold). I had enough trouble getting them off during the removal, however am not able to get them reinstalled now that everything is back together. Im sure there is a special tool for this but Im hoping to be able to get this done without towing it to a VW shop. Nothing against shops, just that my labor is free. Any suggestions???. Help would be appreciated.

[BaggedGLI]

Re: Need help with mk2 exhaust

I usually take a couple screwdrivers, jab them in there, and wiggle, a little WD40 doesn't hurt either, just don't get it in your eyes.

Once you are at that point, just swear and wiggle.

[Kunu]

Re: Need help with mk2 exhaust

Ive gone so far as to fabricate my own tool to help pull them downwards (working from under the car) but I still cant get them stretched far enough to link over the down pipe. Dont get me wrong, Im a huge VW fan, but this has to be the most retarded piece of engineering I have ever seen. Maybe I'll just put on a new manifold and exhaust system so I can avoid this in the future!.

Thanks for the tip.I'll give it a spin.

[Stonewall]

Re: Need help with mk2 exhaust

Take a look here: http://www.metalnerd.com/cat08.htm
Exhaust Clamp Spring Spreader

This specialty spreading tool is the best way to deal with those C-shaped spring clamps used to attach the exhaust down pipes to the exhaust manifolds on Rabbit (A1 chassis) and some early Golf/Jetta (A2 chassis). This spreader removes and installs the C-spring clamps with ease! Has a 3/8" square drive on each end so that it can be actuated from the hood or from under the car. All steel constructed, zinc plated to resist rust. Quality European manufacture.

[Kunu]

Re: Need help with mk2 exhaust

Wow, I guess specialty tools do serve a purpose............although $65??. Maybe if I was opening an exhaust shop or something along those lines. Thanks for the heads up though. Thought about it and talked to a few guys at work (work at a GM dealer in Calgary) and found one of the new tech's worked in a custom car shop doing exhaust work - long story short, he fab'd a spreader using a length of hatch support rod shaft. Worked like a damn. Shes nice a quite again.

Thanks for the tips guys. Appreciated huge!.

[vee_dubbin]

Re: Need help with mk2 exhaust

Did you end up solving the overheating problem yet?

[Kunu]

Re: Need help with mk2 exhaust

That remains undecided - I think so, but the thing runs like sh!t once the engine gets warmed up. Doesn't seem to be pushing exhaust gas through the cooling system however I think its over fueling itself now, but I dont know enough about these things to be able to diagnose it properly. The overflow container wont hold pressure so as it warms up and coolant expands, it just bubbles out of the overflow ports......I bought a new one (correct for this car) but it didnt' come with a cap or level sensor so its yet to be installed. Erik also got me the two coolant sensors that install at the front of the engine but one was wrong so im waiting on that as well. Very strange - the car runs soooo perfectly when its cold but at idle (perfect 950 rpm with no warning lights or misses), but after about 20 mins it starts to sputter and misfire and smoke and run really rich it seems. Wont stall, but it misfires and barely responds to throttle input. I let it go for about 10 mins like this the other day and found the exhaust (cat converter) almost burned the car down. Shut it down with smoke coming through the shifter area. Let it sit for about 30 mins and the car runs fine again for another while, then goes right back into the funky chicken. I think Lawrence might see it show up at his shop unless I can come up with something that solves the issue.

On a more positive note, I was in need of a victory with this thing, so I chopped the front springs today after work - looks rad. Need to remove the rears to get them cut but Its alot better for the time being. Any thoughts or suggestions????. Im taking all notes from anyone at this point..................Except those of you who say to ditch the project and move on to something else. Im not interested in laying down on this car, I love it!.

[dubCanuck1]

Re: Need help with mk2 exhaust

The trick with the exhaust clamps is to put the nuts on first, then the collar with the "C" part facing away from the throat of the "U". Then, undo the bolts on the clamp until the clamp stretches out. I had made a special tool like metalnerds, but it didn't have the hex sleeve to keep the tongs straight.

I'll try to dig up the pic of the clamps in action.

Edit: just saw you already solved the problem.

[100%VAGitarian]

Re: Need help with mk2 exhaust

replace the thermostat and fan switch. also the blue coolant temp sensor. make sure all your grounds are good, especially the ecu and o2 grounds.

[Kunu]

Re: Need help with mk2 exhaust

replace the thermostat and fan switch. also the blue coolant temp sensor. make sure all your grounds are good, especially the ecu and o2 grounds.

Thermostat was done before I bought the car (replaced by an audi/VW tech who I know and trust). Replaced the blue coolant sensor the other day (thanks to Erik from R.O.A and C.A.W for the parts and input)............So here's where Im at with all of this. It seems this is turning into a "diagnose the decrepid" mk2 and Im totally cool with that as I need all the help and suggestions I can get. As stated in prev. posts, I know enough about these cars to get myself into alot of trouble and debt. HAhahahah.

Replaced the overflow container and the blue coolant sensor. Started the car and it ran perfect again........until it got warm (about 20 mins of idling) then started to smoke and gag and puke like it has been since the head gasket was done. I decided to do the block check that I was avoiding. To my delight and amazement the fluid stayed blue!!!!!. The car ran for the standard 20 minutes and then started to wig out again but still the fluid in the block check vile stayed blue - good news!!!!. Baffled to this point I started to trace my steps when I put the engine back together trying to see if I forgot to reconnect something - but everything is plugged in, or tightened down (except the alternator adjuster bolt but that has nothing to do with it). tried unplugging the o2 sensor, but no better. Tried unplugging the coolant sensors and still no change - Then I pulled the (forgive my north american car terminology as I dont know what VW called it back in '89) Mass air flow sensor harness and low and behold, the idle stabilized, the car ran great again, stopped dumping carbon out of the exhaust, and from what I can tell, leaned out again. Great, so now I need to replace the sensor?????...........or is this just a diagnostic aide to something else????????. When the sensor is unplugged it runs great at idle, but doesn't respond to throttle input naturally so I cant drive it. Do I replace it?????.