EXHAUST SYSTEM 1.9DG (EARLY TYPE >8/85)

[Bowton Lad]

Next Monday my van is going into a garage in Bolton to have a complete new exhaust system. The 4 manifold pipes & the tail pipe have been purchased from GSF & the genuine VW back box from Devon Dave.
Engine: 1.9DG Petrol 1983 with early type exhaust.


All the old bolts/studs with nuts are so rusty that it's impossible to tell which are which. There are 4 manifold pipes, 2 on the nearside & 2 on the offside. Are these secured by bolts through the flange on the manifold pipe or are they secured with studs (ie.threaded both ends) & nuts?

GSF didn't have a clue but 'thought' that I would need 8 studs & 8 copper nuts. I hope they are right! I do have 6 short 8.8M bolts 2 slightly longer so I should have both options covered. Dr.Haynes does refer to bolts but is rather vague on the subject.

I have looked in the Wiki but there is just a diagram of the later 1.9DG exhaust (ie.8/85>) but no further information.

Does anyone know for sure how the manifold pipes are secured?

[trundletruc]

It is a long time since I changed the exhaust on my van but I seem to remember that there were studs with nuts at the front of the engine but at the back there was a mixture of studs and bolts.

To get the nuts off the studs, if they will not undo, saw close to the side of the studs, in line with the stud, so that one side of the nut comes off. A junior hacksaw is best. This usually weakens the nut and an adjustable spanner or mole wrench will then move it on the large flat you have made. If not, saw off the other side of the nut and it should come off. The amount of thread that you accidentally take off the sides of the stud will not seriously effect its ability to hold everything together with new nuts.

Hope this is useful.

[toomanytoys]

There should be 2 M8 studs and nuts on each exhaust port.. trouble is the studs wont come out easy, so I hope the mech you are using will be good..
Bolts are ok to use but make sure they are not to long... lots of copperslip..

You need a fitting kit for the silencer.... 2 gaskets and bolts and nuts/nuts

[Bowton Lad]

I dropped the van off at the garage in Bolton yesterday afternoon so the mechanic could start work as soon as he got there this morning. It turns out that he actually started work on the exhaust last night.

Anyway, he phoned up at around 2pm this afternoon & said that he had finished & he got all the studs out without any shearing off. Phew!!!
The new system is on with all studs copper slipped & the van is now so quiet that it actually seems strange not having all that throaty exhaust sound. I think the price (labour only) was very reasonable @ £100.00 given the work involved.

[toomanytoys]

Bargain that and must have known what he was doing....

[phredd]

Well done that man
Phredd

[fairwynds]

Crikey! Good job.......

[Ian Hulley]

I dropped the van off at the garage in Bolton yesterday afternoon so the mechanic could start work as soon as he got there this morning. It turns out that he actually started work on the exhaust last night.

Anyway, he phoned up at around 2pm this afternoon & said that he had finished & he got all the studs out without any shearing off. Phew!!!
The new system is on with all studs copper slipped & the van is now so quiet that it actually seems strange not having all that throaty exhaust sound. I think the price (labour only) was very reasonable @ £100.00 given the work involved.

Steve, probably someone more members in your area would like to know .... £100 for the labour is Superb ... there's not many that'll touch these old crates.

Ian.

[Bowton Lad]

Steve, probably someone more members in your area would like to know .... £100 for the labour is Superb ... there's not many that'll touch these old crates.

Ian.

The garage that did my exhaust is:-

AJ MOTORS
STANLEY MILL
KIRKEBROK ROAD
DEANE
BOLTON
BL3 4JE

TEL:01204 62496

Access to the garage is via Harrop Street at the top side of the mill, it's located at the back corner & can't be seen from the main road. Stanley Mill is the new name for what was always known as Wharf Mill.