Hhheeeellpppp!!!

[connorp]

I'm trying to fit a gti6 inlet manifold to my 1.8xs and there's 2 hoses going to my xs inlet and 3 to the gti?? What's the top one in the photo??

All help much appreciated as the cars in bits at the moment :/

[welshpug]

top one is brake vacuum.

[cully]

lower small goes to the charcoal canister
middle larger goes to the rocker cover breather
top as welsh says Vacuum for servo

[connorp]

Now this.. How can I overcome this pipe in my way? It's connected to a thing that's connected to the alternator belt

[Dum-Dum]

The gold one is vac and runs to the brake servo.

[welshpug]

power steering, bend it, or use gti6 pipes.

[connorp]

But there's this one too.

[Toms306]

The thing connected to the aux belt is the power steering pump...so kinda important. That is the high pressure pipe for the PAS. I don't know how you get around it when fitting the GTi mani though, is it really in the way or just touching?

[connorp]

Really in the way, I've just bent it though haha

[Dum-Dum]

The PAS pipe can be tapped out the way with a big hammer being careful not to kink it.

The second photo is too close in for me to see your issue, can I have another photo please.

[connorp]

Far away pic so you can work our where it is, that's looking at the manifold as though you are looking from the back of the car

[Dum-Dum]

That is the ICV hose, it needs either a separate filter or plumbed into the intake hose.

[connorp]

Nice one, cheers man, almost done

[Dum-Dum]

Good stuff. IIRC garden hose goes over the pipe on the ICV so you can locate the filter for it anywhere.

[Eeyore]

Yeh just bend the pipes out of the way. I fitted a small filter to one of the outlets. Just cable tied it on.

[connorp]

Where does this go!??
I've only got to plug this in, fuel lines and throttle cable

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Actually wait, no I know where that goes

[connorp]

Put it on and connected everything, I think but when I turn the car on it idles at like 4k revs?? What the hell is up with it?

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What should be plugged into this top one?? Please as I don't think I have anything to plug into it

[Dum-Dum]

Have you connected the TPS, ICV and MAP the right way around, IIRC they are all 3 plug things.

Are you sure that you don't have an air leak?

As for plugged into the top one do you mean the map sensor or the breather hose?

[connorp]

Could the air leak be between the inlet manifold and the engine block? Because the bit the bolt holes are on is thinner than the old plastic manifold??

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The one that sticks out and then turns 90 degrees to be facing upwards

[welshpug]

massive air leak or dead icv, map and icv cannot be mixed up, nor tps.

blue two pin plug is either pas pressure sensor or gauge sender on thermostat housing.

[Dum-Dum]

Does that help?

[attachment=23639]

[connorp]

Yes it does!! More than you can believe

[Niall]

You have an air leak. Take the manifold off and check both faces. Even the smallest of bits of dirt can can cause a leak. I bet you have a bit of the old gasket stuck on there!
The sensor on top is your map sensor. If you don't have a plug for it, take the map off of your 1.8 manifold and use that. It will fit and work fine. Its on the underside of the manifold on the 1.8, probably a blue label on it.

[connorp]

I'm calling it a day for today and I'm going to take the day off work tomorrow and hopefully sort it, I've been trying since 11 this morning and have had enough of it!!

[Dum-Dum]

Did you get new bolts to make sure the manifold is tight as some of the originals are far to long and the bolts not being tight might be the cause of your air leak.

[connorp]

I haven't got new ones no, i'll get some in the morning and try that, because it all feels tight but I know for sure that one of the bolts isn't tightened onto the mani because the washer at the bottom spins. I'll let you all know how it goes tomorrow, and please check back here tomorrow because I will undoubtedly need to know more stuff

[Dum-Dum]

Cool, I'm off work tomorrow so can check. There is a few of the bolts that are too long and feel tight because they bottom out in the holes in the head. If you can't get shorter ones just wind a nut under the head and you can make the original bolts that way. I think all the allen head ones are too long but the suds still work fine.

[attachment=23640]

[connorp]

Yeah that's exactly it I'm going to work tomorrow now, because i'll either be able to get shorter bolts or do what you've done, any idea on what thread they are?

[Dum-Dum]

Standard M8 mate. B&Q, Homebase and Wickes all sell them but screwfix would be cheaper.

[connorp]

I work for an engineering firm so i'll just get them from work cheers mate