1.9TD exhaust query

[talkingwhippet]

Hi all,
been sorting out my camper that I bought back in March.
It had already been converted to AAZ from a CS diesel - although conversion pretty poor.

Looks like they've retained standard AAZ exhaust manifold & turbo, but then welded CS exhaust pipe to it. Larger diameter pipe with big olive shaped bit in woven wire comes out of manifold joint - after that smaller diameter pipe welded to it.

Silencer is a bit crap & baffles inside are rattling, so want to sort it out with proper replacement. Sure that on Brick-yard somewhere also says about having larger diamter pipe for AAZ to run well.

What do I need to buy so that I can use stock pipes & silencer - will stock T25 exhaust (assuming 1.6TD would be ok) bolt straight onto AAZ manifold? If not what needs sorting?

All help & advice gratefully received as usual.
Cheers.

[ELVIS]

i had same set up . take AAZ downpipe , disc cut off pipe leaving just flange , take to machine shop and get flange centrebored to get rid of old weld/pipe.
use a JX exhaust box and a JX downipe . you have to cut n shut JX downpipe though but no big hassle - just bolt flange to turbo and mark for best position and stick as couplt of tac welds on.
JX pipes are about 10mm bigger than AAZ !!!! CS ones are like peashooters- aswell as strangling engine/stopping turbo from spinning up as quick i would guess it would also increase exhaust gas temps but quite an amount - not good!
If you can live with it/lazy/cant get to a welder etc etc just run an open pipe with no muffler for a while - turbo absorbs most of the noise anyway and the increase in performance is noticable due to turbo spinning up quicker.

[talkingwhippet]

Hi Elvis,
when you say "cut 'n' shut" JX downpipe, do you mean that pipe itself has to be cut & then rewelded at different angle so will actually fit AAZ manifold & end up in right place for silencer? Have offered up JX downpipe to manifold, & silencer end points up at bumper!!

Have done what you suggested for now & junked existing silencer - turbo running no probs now - how long can I run it like this?

Any other thoughts on exhausts for AAZ turbo/manifold set-up gratefully welcomed.

Cheers.

[ELVIS]

because the AAZ turbo/manifold is in a different position/orientated differently to JX it will take a bit of very minor engineering/welding and wont fit staright out of the box, hence using original AAZ flange and cutting JX flange off the downpipe and tacking the JX downpipe into new position onto AAZ flange.
The JX pipe is actally a larger bore than the AAZ by 1/4" or so !!
i used www.jetex.co.uk , they sell all sorts of bends/pipe etc for sensible money. £20 should see you with the bits you need.If you have a full JX downpipe you can use this to cut up for straight bits.
If you run without a box it will be a bit noisier but turbo absorbs most of the noise. If you do run with no box make sure the tailpipe exits past the bodywork , stops soot/"pooh" getting into engine bay and also stops noise echoing around engine bay aswell (think it might be an MOT requirement aswell). You will find with no back box the turbo spins up a little bit quicker so engine will slightly more responsive.
I did it this way as i bought a complete AAZ with a good turbo and my JX engine was dead as was the turbo and i couldnt afford the £300/400 for a new JX turbo ontop of the engine cost.
I wanted a decent install , not a cobbled together piece of "pooh" so got the downpipe fabbed by a mate for a pennies.Spend a few extra quid and get it done once and done properly.