How to remove the exhaust manifold on the Polo sedan

Collector Volkswagen Polo

To supply the fuel-air mixture into the combustion chamber and the removal of exhaust gases serve the intake and exhaust manifolds. Their work is associated with a constant impact of thermal and mechanical stresses.

This leads to frequent cracks that interfere with normal engine operation. Since the cost for a new manifold is high, many car owners resort to brazing and welding the resulting damage.

Item number and cost of manifolds for Volkswagen Polo

The original exhaust manifold Volkswagen Polo sedan has VAG part number 036253056F. Its cost starts from 12 thousand rubles. It is possible to purchase the product from car junkyards. In this case, the price will be from 6 to 8 thousand rubles.

There are also analogs of the original exhaust manifold on the Volkswagen Polo. The most popular are parts for Skoda Fabia with part numbers 036131703G and 036131703J. The cost of the products is about 4500 rubles.

The original intake manifold has VAG article numbers 16CA86851 and 045129713Q. The price for a branded product is 9-14 thousand rubles. A used version can be purchased for 2-4 thousand rubles.

A good analogue of the original intake manifold is a part for the Volkswagen Caddy with part number 036129711fm. The cost of the product starts from 5-6 thousand rubles.

Tools required for the dismantling and installation of manifolds

In order to remove and install the intake and exhaust manifolds you will need a list of tools listed in the table below.

Name Note
Screwdriver Screwdriver Flat blade
Knife To clean the old gasket
Wrench “12”, “13” screwdriver
Head “12” socket
Penetrating grease WD-40
Allen wrench To remove the intake manifold

The process of removing and installing the exhaust manifold, replacing its gasket, as well as fighting cracks

Underhood noises often indicate a crack in the exhaust manifold body. In order to detect damage, it is necessary to visually inspect it. You can do this either directly on the car or by removing the manifold. The appearance of the crack is shown in the photo below.

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The appearance of the manifold, with the crack

In order to solve the problem of a cracked Volkswagen Polo manifold, it is recommended to use the instructions below.

  • Unscrew the fasteners circled in the image below.

Manifold fasteners unscrewing

  • Dismantle the oxygen sensor, circled in the blue oval, and unscrew the bolts securing the thermal protection.

Location of oxygen sensor and bolts fixing thermal protection

  • Remove the thermal protection.

View after thermal shield removal

  • Remove the bolts fixing the exhaust manifold to the cylinder block.

View after disassembly of exhaust manifold

  • Remove the gasket. Its reuse is not recommended, so you need to buy a new one in advance. It has the part number VAG 03C253039H. Its cost starts from 400 rubles.

Dismounted exhaust manifold

  • You can solve the problem with a cracked exhaust manifold in several ways:
  1. Purchase a new product. The most expensive option.
  2. Buy an old manifold from auto junkyards. The remaining life in this case will be unknown.
  3. Weld the old collector. Keep in mind that incorrect welding will lead to the appearance of new cracks after a short period of time.

Welded manifold

  • Reassemble everything in the reverse order.

Dismantling and mounting the inlet manifold and replacing its gasket

In order to replace or repair the intake manifold and install a new gasket, it is recommended to use the instructions below.

Self-removing the exhaust manifold of the Volkswagen Polo sedan

Unconscious understanding of the principle by which the car comes into motion, begins to form as early as childhood. Every kid at least once in his childhood drew a car. The most important thing was to show the outlines of the body, doors, wheels in the drawing. Some of them managed to draw rear-view mirrors. But the most important element was considered the exhaust pipe, which, as a rule, exuded a cloud of gray smoke. In this way it was possible to understand that the car was not just standing, but driving on the road.

In all modern vehicles, the exhaust is routed to the tailpipe. It is a technical appendage of the power plant, which controls the supply of the fuel-air mixture into the engine cylinders, as well as unquestioningly removes the exhaust gases from the system. Accordingly, two devices are provided for two purposes – an intake manifold and an exhaust manifold.

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Outlet manifold

The purpose of the first is to distribute the hot mixture evenly over the cylinders. Clogging one of the pipes can lead to an imbalance of the injection, which causes malfunctions in the engine and reduces its performance. In addition, the vacuum that is created in the system is used to control other parts of the car – power brakes, cruise control, power windows, etc. In the intake manifold chamber, the crankcase gases resulting from driving are combusted. The first intake manifolds were made of aluminum or cast iron. Today, the devices are made of plastic, which is more resistant to temperature, allowing the cylinders of the power unit to be fully filled and its performance stabilized.

Exhaust manifold design

The exhaust manifold is an element of the car’s exhaust system, through which internal combustion products are exhausted. In order for the fuel-air mixture to enter the cylinders faster, the pipes and chambers of the exhaust manifold are blown. Two types of devices are installed on modern cars – one-piece and tubular manifolds. The first examples are cast-iron products with short tubes combined into one common chamber. The exhaust is slower than on the tubular examples, but the low cost of the devices compensates for this disadvantage. Tubular exhaust manifolds cost more than solid ones, but the steel construction of the combustion engine element is much more effective in coping with the “extraction” of combustion products.

Manifold connection to the system

On the Polo sedan, the Kaluga car factory installs tubular samples. The most important “neighbor” of the exhaust manifold is a catalytic converter. It is designed to reduce the toxicity of exhaust gases. It is considered “main” because it is not cheap on the car market. The original part together with a manifold for Polo sedan costs well over 50 thousand rubles. Environmental protection is expensive.

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Between the tubes and the combustion chamber on the outer surface lies a heat shield, which is attached to the device with two flat-head bolts. It acts as a lifesaver, protecting the device from the formation of cracks in the body and the ingress of moisture, which in the worst case can provoke a breakdown of the device. The original with the article number 036 253 041 CR will cost owners of a Polo sedan under 2000 rubles.

Thermal shield

There is a special gasket 03C 253 039 H in front of the tubes connected to the cylinders of the “engine”. The price tag for the German sedan is set in the range of 300-350 rubles. The gasket together with all the weight of the device is kept on the 9 hex nuts. Just buy any do not need, of course, so if you decide to make a replacement device, it is necessary to purchase samples with part numbers N 908 946 01 or WHT 000 001 N.

Special original gasket

It is more advantageous to buy the exhaust manifold for the German sedan as a set than to assemble the parts separately. The unit in online stores costs about 2300 rubles (without neutralizer of course).

Depreciation of parts is common for cars. The exhaust manifold is the same problem. Russian roads often become insurmountable obstacle for these far from fragile devices. Cracks, chips and other deformations are the physical side of the medal, which in most cases can be accompanied by unpleasant pops from underneath the car.

Many owners of the Polo sedan solve such a difficulty with welding: remove the part from the car and weld the resulting breach. But, as a rule, on the German sedan this way the problem is not solved, since literally in a few months the “seam” begins to separate. Therefore it is better to change the device for a new one if a crack is formed on the body.

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Manifold crack

Another problem is related to clogging of the exhaust system. The inability to remove combustion products efficiently and effectively, resulting from the formation of soot on the inner surfaces of the pipes and the chamber, leads to the destruction of the exhaust system. The popping noise coming out of the exhaust manifold is a clear indication of a malfunction in the system. Excessive contamination of the entire structure can be caused by various reasons. More often the car starts “sneezing”, spitting into the atmosphere, because of the use of low-quality leaded gasoline, which no motorist is insured against. Filling up the engine oil with high content of sulfur and phosphorus from unproven producers may also cause nasty pops.

Manifold Dismantling Guide

In both cases, whether it’s a breakdown or a common clog, you need to remove the exhaust manifold. On the Polo sedan, the procedure will require “10”, “12”, “14” and “22” wrenches, a Torx T14 and T30 head, pliers and about a couple of hours of free time.

Sequence of actions to remove catalytic converter:

  1. Remove the minus terminal from the battery.
  2. Let’s go down to the car and unscrew the engine protection.
  3. Unscrew the bolts of the lower part of the manifold.

Unscrew manifold from underneath

Unscrew the sensor and bolts

Remove thermal shield

Remove the manifold

If there is damage to the exhaust manifold, the part should be replaced. All gaskets are also recommended to be replaced with new ones each time the unit is disassembled, regardless of their degree of wear.

Despite the fact that the process of manifold removal is quite a monotonous process, it is not worth putting off the procedure for a long time. At least once every two years, you need to force yourself to check the device for defects. Otherwise one day the exhaust pipe of your wonderful “Polik” will turn into a real firecracker, tearing up the air around with deafening pops. Not New Year’s Eve at all.

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