This is more of an email for the archives so if you could throw these in the "HOW-TO" section I'm
sure someone (like me, this past week) will love the list for it someday!!!!

HOW-TO:

Remove VR6 Downpipe from 1998 VW GTi.

<blockquote>
<em>
[[
As per Nate:<br>
The part number for the header is 1HM253087C; it costs $540 from the dealer!
]]
</em>
</blockquote>

Tools needed:

1)  3/8 or 1/2 drive ratchet
2)  Two (2) 12mm open ended wrenches (minimum 6pt, can be 12pt too.  I used both)
3)  "Super Penetrating Lube" all purpose lubricant for loosening rusted bolts
4)  Hammer (well, I needed one)
5)  Access to a lift (desired) but I used "oil change ramps"
6)  12mm, 17mm sockets (either 3/8 or 1/2 drives)

Task:

*Most* (if not all) OBD2 VR6 GTi's (don't know about the Jettas) are two-piece.  Meaning, the
downpipe BOLTS to the Cat Converter.  I hear that there are a few that are one piece - meaning the
cat is PART of the downpipe.

You can unbolt the downpipe from the exhaust manifold first or from the Cat Converter first.  I
don't think it matters.

Cat Converter:
There are three 12mm (yes 12, not 13) bolts at the bottom of the downpipe where it connects to the
CAT.  These bolts are 12mm on both sides - so you will need an open-ended wrench (or maybe another
socket) to hold the other side.  I needed to spray lube on these nuts as they were very rusted.
Once I sprayed them I had to hammer my socket on to make it fit (too much rust).  Be careful, you
can strip these bolts - so make sure the socket/wrench is on tight/level.

You can turn from either side (cat side or downpipe side).
Trust me, the lube works well - and once you get these bolts to move you're in the home stretch.
There should be one at the top which is very hard to get to that an open ended wrench will work
best with - this is why you need two of them.

Once you get those three bolts undone you'll need to undo the harness from the UPPER o2 sensor. 
Because you can't unscrew it from the downpipe until you pull it completely out.  So, go to the
top of the engine and look on the left side in the back (below the throttle body and a bit to the
left).  You'll see two large connectors (I think one is brown and one is white).  The one on the
right is the upper o2 sensor (connects to the downpipe right by the CAT).  Unplug that (squeeze
and pull).  Now go back down to the under car and pull the harness down with it.  This takes care
of that.

Now, you need to unbolt from the exh manifold.
Simple:  Three bolts on each "port".  They are17MM's.  The pipes get in the way of the bottom
bolts so you may need to reach up from the bottom.  I just hopped up on the top of my motor and
reached down.  Surprisingly enough my bolts weren't too tight - nice and tight but not like the
exhaust was!!!!!  I got all 6 done in about 5 minutes.

Now that the downpipe is totally loose you'll need to get it out.

DON'T PULL IT OUT FROM THE TOP.  It won't make it past the ....ahhh, R&P or steering mechanism
(don't know what it is...you'll see it tho).

You need to PULL IT FROM THE BOTTOM down towards your CAT.

PROBLEM:  CAT is in the way...
Slide farther down to the OTHER side of theCAT and loosen the two bolts holding the CAT to the
mid-pipe.  17MM bolts.  Spray some lube on there to make it easier for you.

Use a hammer and theCAT should come free.  There is a lower o2 sensor attached there but there is
enough play where you can let it come down and lay on the floor.

Now you have room to pull the damn thing out from the bottom.  COOL.


I haven't reinstalled yet but my guess is it's reverse of removal so you should be set.

Not sure that anybody cares about this HOW TO but if this were here last week I would have been
alot happier.

Any questions just email me at "nate@nateengel" or nfe100@yahoo

Later,

Nater