In a message dated 12/11/2007 7:28:58 P.M. Eastern Standard Time,
LISTSERV@GERRY.VANAGON.COM writes:

1)   The gasket I got at the dealer has one metal side and the  other
side is gasket material.  Which side goes against the engine and  which is
toward the exhaust pipe?
Metal side to pipe!
2)   Is the correct bolt size M8 x 30mm?  Unfortunately one of  the
holes is stripped.  I'm hoping it is a 20mm bolt and substituting  a 30mm
one solves the problem.
Yes!

3)       What is the correct torque for the bolts?
Depends on bolt quality and never  seize use. ~10-12 ft lbs.

Bentley says the metal side  goes toward the head.  And that's the way I've
been installing them since I  started working on Vanagons some 15 years ago.
Correct length bolt is  30mm.  If the threads are buggerd up you would be wise
to install a proper  helicoil.  If not it's gonna come back and bite you.
Torque according  to Bentley is 18 ft. lbs.  I usually take them up to 20 with no
problem as  long as the threads in the head are good.  Use Stainless Steel
bolt with  anti-seize on the threads.  Below is my "Vanagon Exhaust System
Install"  document I send out with my Stainless Steel Exhaust Systems.  It may be
of  some help.  It's a brand new version I just finished editing yesterday and
have not loaded on my website yet.

     "Start by removing your existing exhaust system.  Remove your existing
muffler hangers.  Remove all bolts and studs  from the engine exhaust ports.
Clean and repair as necessary any damaged  threads in the header ports, clean
the gasket surface and insure they are flat  and level on both the header port
surface and exhaust pipe flange surface, clean  all surfaces with solvent,
lightly coat the header pipe gaskets with Loctite  Ultra Copper High Temp RTV
Silicon sealant,  place the gaskets in position,  flat metal side against the
head and bolt the header pipes to the engine using  18 ft.lbs. torque.  Do not
install the push rod tube covers at this time,  you can loosen the lower header
bolts later when your finished installing  and testing the exhaust system to
install the push rod tube covers.  Now install the collector insuring the
surfaces are flat and clean using  the sealant on the gaskets here also, now
install the J-pipe but do not tighten  the bolts at this time, instead install the
muffler mounting brackets and do not  tighten the bolts, install the CAT to the
muffler  Please note that some  CATs do not have the inside bevel to accept
the doughnut gasket.  If your  CAT does not have the necessary bevel you must
create it.  Using a rotary  grinding tool, bevel the inside of the flange and
tube to a 45 degree angle so  that the doughnut gasket will seat well in the
end of the CAT.  Click  HERE for picture detail. Leave the bolts loose enough so
that the CAT can  be rotated on the muffler flange, install the muffler and
CAT assembly in the  muffler mounting brackets, connect the J-pipe to the CAT
and do not tighten the  bolts, adjust the muffler, muffler brackets, CAT and
J-pipe tighten the bolts  slowly as you proceed so that the tail pipe is below
the rear valence but does  not touch and the muffler to CAT, CAT to J-pipe and
J-pipe to collector  connections are as straight as possible.  Once your
satisfied with all  clearances, connections and adjustments, tighten all
connections to 20 ft.lbs.  Install the OXY sensor, OXY sensor guard and connect.  If
your old  OXY sensor guard is missing or damaged you can get one form your VW
dealer or  order it from me.  Start the engine, check for leaks, if none, good,
if  any, shut off engine and repair, after there are no leaks with the engine
running, run the engine for 15 minutes, shut off, let cool, install the push
rod  tube covers and check all connection to insure they are tight.  Now it's
time for a test drive with your new Stainless Steel exhaust system.  Enjoy  !

Important Notes:
Use Loctite Ultra Copper High Temp RTV  Silicon sealant on all joints &
gaskets.
Make sure all mating surfaces  are flat and clean, especially those on the
heads.
It is highly recommended  to repair all exhaust port flange thread holes
before installing your new  exhaust header pipes. For best results install
helicoils in all threaded holes.  Then use new stainless steel bolts of the correct
length as the ones provided.  Using bolts of the correct length is critical as
too long will crack the head  upon tightening and too short will not provide
adequate sealing pressure.  Remember the lower bolts all the exhaust ports must
be long enough to  accommodate the tab of the push rod tube covers. You can
modify the tabs of the  push rod tube covers by making the holes into slots so
that they can be  installed or removed without removing the bolts. Make sure
that all holes in the  header pipe flanges line up with the exhaust port holes.
If necessary tweak the  header pipes so that the holes line up properly and
there is no tension on the  sides of the bolts.
Check the CAT. One end may not have a bevelled surface  for the doughnut
gasket provided at the muffler connection. You will have to  create the bevel with
a rotary grinder.  Click HERE for picture  detail.
The connections at the muffler inlet and both ends of the J-pipe use  loose
flanges with doughnut gaskets. This feature will allow the installer to  adjust
the system to insure the least amount of joint stress.
Re-tighten all  flange connections after the system has reached operating
temperature.
Check  all flange connections periodically for tightness.
The OXY sensor  provided is a BOSCH generic model. You must cut and splice on
your old OEM  plug to the new sensor. Wire joints must be connected with the
provided crimp  connectors and covered with the provided heat shrink. Stager
the joints so they  are not near one another. Cover the entire wire with
suitable  automotive high temperature split loom or similar material.  Insure  the
OXY sensor guard is in place.""

Cheers,

Frank  Condelli
Almonte, Ontario, Canada
'87 Westy & Lionel Trains (_Collection for sale_
(http://members.aol.com/Fkc43/trainsal.htm) )
_Frank Condelli &  Associates_ (http://members.aol.com/Fkc43/busindex.html)
- Vanagon/Vanagon Westfalia Service in the Ottawa Valley
_Vanagon Stainless Steel Exhaust  Systems_
(http://members.aol.com/Fkc43/stebro.htm)
_BusFusion_ (http://members.aol.com/BusFusion/bfhome.htm)  a VW Camper
camping event, Almonte, ON, June 07 ~ 10,  2007