exhaust and intake for a 1.9 diesel

Post by **weldore** » 13 Jul 2009, 16:18

im assuming that anyone with an aaz conversion didnt stick with the standard 1.6 d exhaust.ive got the 1y in and am using the 1.6 manifold and exhaust but ive got the stuff to make the 1y manifold work..i.e. 50mm tube and bends and was wondering what exhaust will compliment them.
fabricating new brackets onto a non vw back box is not a problem so if you know of anything that will fit along the back but perform better id be interested..cheers..dave

cheap as possible too

Post by **richieadkins** » 14 Jul 2009, 19:11

I am in the process of fitting a 1y to my van but have managed to shear off the exhaust manifold to downpipe studs from my cs engine. So would be very intrested to know how you get on with this particularly if it means I can keep the 1y manifold.
Does anyone know whether it is possible to keep 1y exhaust manifold and use the standard 1.6 exhaust and how I would go about this??
Sorry for hijacking your post weldore!!!
Thanks Richie

Post by **weldore** » 14 Jul 2009, 19:45

hi richie,i dont mind anyone asking questions about anything on my threads mate

.
if your using the 1.6 d n/a you will notice how small the diameter of the bore is in the manifold compared to the 1y.i think this will stop the engine from breathing as it should..the volume of air it is pushing out will be compressed by the smaller hole in my opinion so im attempting to 'help it breath better'.
its just the silencer is a smaller bore too so i was interested to see if anyone had managed to use a silencer with a larger bore.i might just go to my local auto spares and see what they have in stock..hopefully something around the 20 quid mark would be available for me to dick around with.i also wanted to know if a middle box would be any good to use as the silencer ,not sure if they are different inside to a back box or the same sort of thing, because they are usually tube shaped.any advice welcomed chaps

oh and as for your sheared bolt...try soaking it in penatrating oil for a while then get the mole grips out on the thing..thats how i got mine out ,and if you wanted to use the 1y manifold with your 1.6 silencer you would have to fabricate a new downpipe ,like i am

Post by **camper** » 15 Jul 2009, 16:05

I fitted a 1y engine as a replacement for the 1.6td.The 1y exhaust manifold and a refabricated 1.6td exhaust pipe to the 1.6td silencer is a good choice.Done this by cut&shut the down pipe and extra metal added to bolt up to the manifold.

Post by **ringo** » 15 Jul 2009, 20:00

I was under the impression that to fit the 1Y manifold there was some serious cutting of metal involved.

Its so big there's just not the room. I'd like to be proved wrong mind

It does look a lot better (ie bigger)...

Ringo

Post by **weldore** » 15 Jul 2009, 20:04

think thats for the inlet ringo..the exhaust manifold should go on no probs..agree with you though..the inlet would be alot better

Post by **weldore** » 15 Jul 2009, 20:13

camper wrote:I fitted a 1y engine as a replacement for the 1.6td.The 1y exhaust manifold and a refabricated 1.6td exhaust pipe to the 1.6td silencer is a good choice.Done this by cut&shut the down pipe and extra metal added to bolt up to the manifold.

did you try the old set up to begin with to compare it to camper ?..also mine was the 1.6 d..not td so i think the manifold and downpipe that i had could possibly be a smaller bore than the one you had to start with

Post by **weldore** » 15 Jul 2009, 20:26

this is just a project to see if it makes any difference to the standard 1.6 set up i have,hence why i want to do it as cheap as possible and dont want to start cutting into my original downpipe

Post by **camper** » 16 Jul 2009, 06:33

ringo wrote:I was under the impression that to fit the 1Y manifold there was some serious cutting of metal involved.

Its so big there's just not the room. I'd like to be proved wrong mind

It does look a lot better (ie bigger)...

Ringo

The 1y exhaust manifold will fit & no cutting but the 1y inlet manifold reqiures engine bay side panel cutting or other to fit.The 1.6td exhaust down pipe is larger than a 1.6n its a good choice & the 1.6td silencer.The 1.6td down pipe where its bolted to the 1y manifold require extra metal then drilled to match + cut & shut angles to fit to the 1.6td silencer.Done this bit of a fiddle to get the bends right .Weldore the 1.6n& 1.6td down pipes will not bolt up or fit to the silencer unless as in my discription .To get the bends for the down pipe to fit the 1y one method is to use a stiff wire bent & routed from manifold to the silencer then compare this against the 1.6td pipe make some cuts& mig weld good tacks before you fully weld.When you are sure it will fit fully weld the pipe .

Post by **billy739** » 16 Jul 2009, 08:09

have a look at a 1.7d manifold.

the down pipe is thicker!

may be worth a try.

will take a look later as i have a 16 and 17 pipe to compare.

Post by **weldore** » 16 Jul 2009, 18:15

thanks for the interest guys..yeah thats the bit thats a pain really..how to connect it to the silencer.i do have a spare downpipe that i could taper into the new bigger downpipe that im gonna fabricate(when i get round to it

) but if i can find something to match the 50mm tubing i have it would be better..might have a trip down the scrapyard and mooch about there

Post by **richieadkins** » 16 Jul 2009, 19:42

Was just thinking, might be completely stupid (feel free to tell me so), would this be any good???
http://cgi.ebay.co.uk/EXHAUST-FLEXIBLE- ... tsupported

Post by **weldore** » 16 Jul 2009, 20:16

not stupid at all..to tell you the truth ,i thought that maybe the whole topic might be stupid when i posted it as no-one really has ever brought this up

the idea would work but it still leaves me with the problem of connecting it to the exhaust and the flange on the manifold.i have a 8mm plate with the holes for the bolts and a 54mm center hole for the bore for the manifold...some 50mm x 3mm tubing and about 6 90 deg bends out of the same stuff....its used for making hand railings normally but with the thickness i thought it would prolly last the van out and if i can source an exhaust to match what ever end i put on the downpipe that will be just peachy

the breakers is looking good so far

oh..and how did you do that with your last post

Post by **richieadkins** » 16 Jul 2009, 20:50

If you highlight the link then click on the URL button above the text box then submit post it will then create a link in the post if that makes sense

Post by **weldore** » 16 Jul 2009, 20:58

richieadkins wrote:If you highlight the link then click on the URL button above the text box then submit post it will then create a link in the post if that makes sense

but how did you get it to fill the whole box and shove ya avatar n stuff out the way ?

oops..musta bin i.e 7...just got i.e 8 after getting a virus and your post is ok now....wierd

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exhaust and intake for a 1.9 diesel

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