exhaust and intake for a 1.9 diesel

Post by **caveman** » 22 Jul 2009, 22:25

Yes please i need to see some pics

Post by **richieadkins** » 23 Jul 2009, 06:23

Me too!!!!

Post by **weldore** » 23 Jul 2009, 07:23

on this one i used a section from the old downpipe i had and welded it into the end of the 50mm to make the connection into the exhaust

Post by **caveman** » 24 Jul 2009, 14:23

I think you should weld in some kind of flex joint in the pipe somewhere. Otherwise it may tear the muffler mounts or even break the pipe at it's weakest spot, sometime on a sunday night during a downpour.

Post by **weldore** » 24 Jul 2009, 15:28

hmmm...we think alike....i was thinking of taking it to work next week and putting some real good welds on it...i smoothed the welds off to see if i had any leaks..and there were a few so i sorted them out,but in the back of my mind i keep thinking if it were to break ,i wouldnt want to be behind me when it did ..so its going to get some better weld on it.i might even get one made up in stainless but a smaller guage yet....it was just an experiment and it has made a bit of difference to the pulling but one hell of a difference to the sound

Post by **psychonaut** » 30 Jul 2009, 06:56

I've really enjoyed reading this thread - it's good to know other folks are sharing my troubles!!

I've just had a 1.9 diesel put in my '81 van, to replace the 'orrid 1.6 that was in there and kept blowing up

The engine came out of a '98 Seat Ibiza, with the larger bore exhaust manifold you all mention, but the exhaust on my van is of the smaller bore that you guys vare talking about, as it was a 1.6. It makes it very noisy in the van - almost impossible to hold a conversation oif any kind with anyone in the van, even someone in the pax seat.

I've bitten the bullet and got her booked in next week with a custom exhaust maker here in Cardiff, who'll make me an exhaust and fit it, at the larger bore to match the 1y engine's exhaust manifold. Not cheap, but it'll be stainless steel and made to my exact specifications. He can even make it quiet or loud for me, depending on what i want. As i have several loud motorcycles, i think i'll go for the quiet option with the van

As soon as i've had her done and got her back, i'll post photos for you to see.

As for the air intake, i've currently got a K&N-type filter taped on the end of the inlet. Not ideal, i know, but that's next for my attentions. Can anyone help me out with an ideal solution to the known problems of sorting out the air intake?

Post by **weldore** » 30 Jul 2009, 08:29

well....i dont think it makes much of a difference but they say about port matching the 1.6 inlet manifold with the 1y block...but...if the noise is terrible i think it will be your k+n....when i first did my 1y swap i didnt bother with the intake pipes up the side of the van or the box that sits behind the rear lights,mine was all split so i left em off.went out in it and it was so loud you had to really raise your voice to chat,decided to put the extra bits back on and used some duct tape to sort out all the splits and it was like id gone deaf compared to before..it does make a hell of a difference..id say your k+n is booming making it loud..was that what came with the van when you got it?

Post by **weldore** » 30 Jul 2009, 12:15

oh..and have you noticed the power difference...its not vantastic on mine but better than waiting for the 1.6 to build up speed..if it ever does

when you are used to driving a normal diesel car its a bit of a shock though when you have to drive round with the accelerator half way down or more all the time..they are heavey busses though i suppose

Post by **psychonaut** » 30 Jul 2009, 12:38

Hello Weldore - when i bought the van, it came with the standard air filter set-up, but as you've discovered, it's a booger to fit in with the 1y engine!! What set-up do you have in yours, if you don't mind me asking?

I have noticed a power difference!! Nothing huge, i have to say, but subtle things like getting up to speed much quicker, holding with the flow of the traffic, and not having to drop to 3rd on even the gentlest of hills

Post by **weldore** » 30 Jul 2009, 13:27

mines exactly the same as the 1.6 greg...just used the 1.6 inlet on the 1y,which im guessing you had too coz the 1y inlet need the chassis cutting to make it fit in.you should have the airbox with the filter in it on the engine then a rubber pipe connecting it to another box behind the left rear light cluster(im guessing this is some sort of suppressor box as mine was very loud without it fitted),then from that an oval shaped pipe runs up between the skins of the van to a snorkel thats fitted in behind the grill on the near side rear

Post by **psychonaut** » 30 Jul 2009, 18:43

Thanks Dave. I have the 1.9 inlet manifold still fitted to my engine. Although it was tight, it does fit without touching the sides of the engine bay. The airbox i took off my 1.6 engine was in a bad way, so i sent it the way of the old 1.6 engine, and as a temporary measure i have a cone filter taped to a piece of rubber pipe which in turn is attached to the inlet manifold. But as you say, it is flippin' noisy!! So, i need to either find myself an airbox from a 1.6 diesel, or visit a scrappie and see if i can find something which i might be able to bodge on.

I'll keep you posted

Post by **weldore** » 30 Jul 2009, 19:48

you sure its not the intake knocking on the side wall greg????..i have a spare inlet filter box and the other box i think...but i dont have another inlet manifold..yours if you decide you need em.i was sure that the intake wouldnt fit mate..its gotta be banging on the side causing all the noise you was on about....but ive been wrong before

...put a pic up of it my old

Post by **weldore** » 30 Jul 2009, 19:55

come on pete ..i know your looking

...wot do you think to gregs probem

and did you notice that one of my bumper iron bolts is hanging out on one of the pics

Post by **psychonaut** » 31 Jul 2009, 07:38

weldore wrote:you sure its not the intake knocking on the side wall greg????..i have a spare inlet filter box and the other box i think...but i dont have another inlet manifold..yours if you decide you need em.i was sure that the intake wouldnt fit mate..its gotta be banging on the side causing all the noise you was on about....but ive been wrong before ...put a pic up of it my old

Thanks dood, that's very kind!! I'll gratefully take you up on the offer

Post by **ringo** » 31 Jul 2009, 08:36

I've got a 1.6d inlet manifold but not the box to go on top. (its got the bottom of the box if you get my meaning).

Was saving it for a conversion but you can have it off me for cost and postage.....

Ringo

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