1997 GTI Exhaust Pipe bolts breaking

[Turbo6990]

Hello out there, I"m new to this site and appreciate any help I can Get. I have a 1997 GTI thats consistently breaking it's exhaust pipe bolts where it connects to the manifold. I replaced all of them AND the side mounting bolt and bushing and it just broke that too! Was there some kinda design flaw and if so has anyone found a fix??

 

[captain scale]

Are your engine mounts weak? Is the muffler strap tight?

 

[Turbo6990]

Exhaust bolts

Motor mounts are good< I've checked for tightness and integerity, they seem pretty solid. Where is the muffler strap. All the rubber boots and hose clamps are tight.

 

[jabeard1]

I have 97 GTI as well, and I have broken the manifold bolts probably 3 times. I finally called Seadoo and they said that this has been a huge problem and the only way to fix it was to retap the wholes to a 10mm. They are 8mm right now, this seemed to fix the problem. I have been on the water 3 times since then and no problems so far...

 

[Turbo6990]

Exhaust bolts

Thank you so much for your response. It makes great sense to do that. I spent several years as a machinist, and am actually, alittle disappointed at myself for not thinking of that on my own. Thanks again. Everyone on this site has been extremely helpful and prompt to respond.

 

[ondmove]

seems they didn't really fix the design flaw, because the 98 has 10mm bolts. They have problems vibrating out. I believe the design flaw is all that weight of the exhaust cone, exhaust pipe with two small supports. All that weight is pounding like crazy on the water and on a trailer. WHere the pipe bolts up to the exhaust on the 98, it is on the side a bit. My 97, it mounted almost right on top the motor... a better situation.

 

[Bills86e]

The tuned pipe bolt where the grommet is has to have a flat washer between pipe
and exhaust. The bolt has to have lock-tite, and be screwed in staight. Bills86e