T25 1.6 TD exhaust problem

[Catmint10]

Hi everyone

I recently lost the the connecting pipe on the exhaust, that runs from the manifold, down to the silencer (it's a standard silencer box).
I thought I had sourced the correct replacement from Just Kampers, but my mechanic at my regular garage says it's not got the correct flange (at the manifold end). When I spoke to Just Kampers they said these parts are getting hard to source and this was all they could offer for a 1.6 turbo diesel engine.
So I'm flummoxed. The van is still being driven, but it's sounding less and less healthy every day (should I be driving it with no exhaust??)
I suppose the only other solution is to buy a good second hand engine at some point and replace the whole lot, but this seems an expensive solution just for an exhaust section.

Anyone got any pointers?

Cheers all

Jon

[ninja.turtle007]

Have you tried GSF?

I know they do the J pipe and silencer.

[Oldiebut goodie]

Don't buy from Just Krampers!!!!!!
Easily available elsewhere.
eg HERE

JK shouldn't sell it to you if it is the wrong one and it doesn't fit! (But we all know that they will and do)

[Catmint10]

Thanks both.

I always had a good service from JK before...but yes this time they do seem to have sold me something just for the fk of it.
I have uploaded some photos to photobucket...shows the problem. You should be able to work out which is the old and which is the new part.
Any ideas if the new part could be 'modified' to fit? I think the main issue would be angling the flange to manifold correctly, as at present it's about 30 degrees off.

http://i222.photobucket.com/albums/dd11 ... 296c9e.jpg

http://i222.photobucket.com/albums/dd11 ... 4034d1.jpg

http://i222.photobucket.com/albums/dd11 ... 352a17.jpg

[lloydy]

Looks like they have sold you the right exhaust, your old one is a botched together homemade one. It looks like your exhaust pipe has been shortened? Are you sure you have a JX engine? Maybe it's from a golf (sb?) and is using that exhaust manifold? Might explain why your exhaust has been cut shorter/ reshaped..

[lloydy]

Oh and you won't need to replace the engine, find a longlife exhaust centre, they will make up one to fit for not much money

[Oldiebut goodie]

JK = £40 more!!!!

I agree - looks like a homemade for some reason.

[Catmint10]

Hi

It wouldn't surprise me if it was a home-made exhaust. The whole engine has been botched to fit, and this is why I've been advised by a few mechanics to replace it someday with a proper engine, as it's a real Frankenstein!
The previous owner (who bought it in it's current condition) had a suspicion it may have been out of an old Passat or Golf. If I could get the new part bodged together, that would be something.
The issue now is that there's nothing attached to the manifold at the moment, and I'm worried the turbo is going to screw up if I keep driving it until I can get it fixed!

[Catmint10]

P.S.
This is the engine, complete with bodged cut outs in the housing to make it fit!
Can anyone confirm what it's from?
It ain't pretty, but it works!

[Oldiebut goodie]

It's not the normal JX injector pump. It looks very frankenstein! There is an oil filler cap on the cam cover - that's not normal JX either. It started life as an upright by the look of it.

[Oldiebut goodie]

The easiest way out of it is to do the same to the new one as the one you have - cut it,rotate it and insert a flexi join.

[Catmint10]

Yes, it's a right old mess! This is why I keep having problems and much head scratching when I look at on-line help, photos etc...because they mean nothing when compared to this damn thing! It keeps trundling on though.
I was thinking the same thing re. the new exhaust part....I'm guessing 2 cuts...one at the manifold end (as the flange mountings are at the wrong angle), and then weld back at the desired angle. And then another cut just to shorten the thing so it will attach straight back on to the silencer.
I'm not sure if the flexi is really needed? I read they aren't really necessary on watercooled engines?

[Oldiebut goodie]

Strangely enough the 1.7 diesel one has a flexi in it.

[Catmint10]

I think that would explain it then! All search engines (DVLA/Insurers etc) always bring up "1.7 diesel" when I enter my reg number. But it has a 1.6 replacement engine. But the V5C says 1.6, not 1.7, confusingly.
I think the associated paperwork with the van is Frankenstein-style too!
I guess a flexi would make the join a bit easier when I get the pipe shortened.

[Catmint10]

It's fixed!

Got my local garage guy today to sort it out, had to cut new exhaust pipe in 3 places, re-weld etc, and fit back in place. Binned the flexi, so we'll see how much vibration we get on the longer runs...

And breathe...for now!