cracked exhaust manifold

[Umai Naa!!]

Where is it fouling exactly?

I'm doing a gasket job on one at the moment, so everything is relatively fresh in my mind.

Is this a Darkside manifold?

They list two different ones for early and late T5s with the 2.5 motor.

They also state that there may be clearance issues with the turbo used on the AXE motors, which I find a little odd, as they're the same manifold as far as stock ones go.

[cafa]

Hi
with the manifold loose on studs you can lift it up and just get turbo into position without the turbo gasket and then when you try to tighten the manifold it is hard up against the top of turbo.
we ground a little off the turbo and it still did not fit so then I asked Kamil Rominski if manifold could be ground a little underneath where there are two cutouts for turbo to fit into and he said that manifold is about 5mm thick , so we ground about 1-2mm of that area and it burnt a hole in manifold...so now it is stuffed ..
I now have to either weld old one or get overpriced genuine that will do the same in time.
This manifold is not a Darkside developments one it is from ebay seller is Pegasus Motorsports Kamil Rominski and the pictures of his manifold and darkside look the same.
I AM OVER ALL OF THIS so much time has been wasted at great expense....VW have many genuine maniofolds in stock and do Know of the problem yet they did not rectify the manifold and still sell the same part with no mods that will fail again...really it makes you wonder why anyone would buy a Volkswagon...I will never do it again..

[Umai Naa!!]

I can totally understand your frustration.

I would repair the old one, to be honest. Make sure it is cleaned out of any loose material internally, and replace the gaskets.

[cafa]

Old manifold is welded and bolted up...nearly finished ..only exhaust to go on but will have to wait till Monday my mechanic is as sick of it as I am.....what a NIGHTMARE..

[Sunny43.5]

I can understand you anger and you may recall I was the first to suggest welding the old one up , it has been done many times here and overseas . I suppose between finding the cracks you must have ordered one first and then did the research to see the options . Hindsight is a wonderful thing ask some questions first before diving in with the sharks .
Look I am so glad to hear you have at least got the manifold back and working , I to have been down on VW for some unbelievable technological issues but I do love our VW vans and finally I have learnt to ask loads of questions before parting with my hard earned money . If I did know what I know now I would not have been out of pocket to the tune of $8500 some years back .

[cafa]

yes, thank you ..I do love the multivan..I just wish that VW would take some responsibility and fess up to there poor design....but I will not give up I am in for the long haul..
thanks again

[Sunny43.5]

VW will never fess up to anything unless forced like the Diesel gate scandal , I found that out some years back I highlighted a fault with evidence and they still denied responsibility . Best to move on and like I said ask first before giving yourself a heart attack .PS it did take me while to get over my own personal thing with them .

[cafa]

yes I am beginning to understand and accept the things that I can not change...and VW are too big to take on ....I have considered selling the Multivan over the past couple of years but find I still have it .....other than the Auto transmissions and the exhaust manifold it hopefully will last many more years and if the weld job stuffs up I recon I will replace with an AG manifold they look the goods

[Scouser]

I had a Darkside cast manifold fitted to my 2005 2.5 turbo diesel with no problems 3 months ago. It took my mechanic a day to do the whole job, remove old one and fit the cast one.
If they are the same manifold I would look at changing mechanics...!
Dave

[Doobie120]

I had a Darkside cast manifold fitted to my 2005 2.5 turbo diesel with no problems 3 months ago. It took my mechanic a day to do the whole job, remove old one and fit the cast one.
If they are the same manifold I would look at changing mechanics...!
Dave

Hi from the UK, I have a 05 2.5, and for the last 3 weeks been trying to fit a Darkside manifold. We followed their instructions and still the manifold would not fit. After a few phone calls, they admitted it will need grinding, I told them if it needs grinding any don't they do it before selling them.
I got a refund.
Now waiting for VW to send aOEM manifold.

[Doobie120]

Hi from the UK, I have a 05 2.5, and for the last 3 weeks been trying to fit a Darkside manifold. We followed their instructions and still the manifold would not fit. After a few phone calls, they admitted it will need grinding, I told them if it needs grinding any don't they do it before selling them.
I got a refund.
Now waiting for VW to send aOEM manifold.

I Should have bought a Ford Transit

[Transporter]

I Should have bought a Ford Transit

It’s never too late. You can sell the T5 and get the Transit. Though, I think you’d have much more troubles with 14year old Transit than with the T5.