Club 80-90 Forums

So the 1Y I fitted seems to be running well and is doing the job.
The current exhaust is the original CS exhaust matched with the CS downpipe and manifold. I can see that rust is starting to have an effect on the exhaust silencer so need to think about replacement options.
So

• -I could just swap the silencer for another 1.6D silencer
  -I could go down the custom motorbike exhaust route
  -I could fit the 1Y exhaust manifold and the modify something to fit
  

Am I right in thinking that if I fitted the 1Y exhaust manifold it would help allow the engine to 'breath' easier? (air intake is another project).
If I did fit the 1Y exhaust manifold I would make a custom downpipe and use a stock silencer.

Is the exhaust system diameter the same or wider with the 1Y compared with the CS?
For choosing the silencer, is the diameter of the CS silencer and JX silencer the same or different? Also, is there a difference in the mounts?

I think I used 65mm pipe when I made this one up. (pppping down with rain at present so not going outside to measure it) https://club8090.co.uk/forum/viewtopic.p ... 4&start=75
I had the silencer made to the same external dimensions as the 1.6 ones.
The engine must be pretty choked if you are using the CS stuff. I think that the bore is around 40mm or something like that.

So I'm going to start the process of cleaning up the 1Y exhaust manifold.

Would I be right in thinking this lug is surplus to requirements and I can cut this protrusion off with the angle grinder above the orange line?

Also do I just need the bit below the blue line and the bit above is surplus to requirements?

The red arrow is pointing to some quite well rusted on nuts. 4 in total. And the threaded bits are probably ok with a bit of cleaning up. I'm not even going to attempt to remove them from the manifold, I think that would open up a whole world of headaches.

It was 55mm not 65mm! 65mm was for the inlet manifold.
That is a totally different manifold to what was on mine. Mine didn't have anything extra like that web or flexi - joint. I would do as you envisage myself except that I would replace those studs now rather than have trouble with them later. Get the blow lamp on them and Plusgas and you will most probably take them out when you try to remove the nuts, mine did - that is where the threads will be at their best. I think that there were a couple of different exhaust sizes used on the 1Y as I bought a new square gasket and it was too small with a 45mm bore, yours looks as though it may be smaller.

The outside diameter of that pipe is roughly 46mm

That is quite a difference to mine then - what vehicle was yours taken from, mine was a '98 Caddy.

From a 94 Golf

Is the mouth of your manifold at that larger size then?
Does that mean as mine is constricted to 46mm there, then there is no point going wider along the rest of the exhaust? It does it not matter? Or should I try to source another manifold?

Yes mine is 55mm from the start.
I wonder if your ports are smaller also as I am sure that my whole manifold looks beefier than yours. I would stick with what you have though as I doubt that there will be much gain with changing. Did you look at how I did the exhaust and silencer - it is the same shape as the CS one and the box is the same external dimensions. The worst bit was cutting a 55mm hole in a piece of 10mm stainless plate for the manifold join. I could have paid someone to do it but I like to do things myself if at all possible.

Looking through ebay I can see lots of manifolds with an extra hole, does yours have one of these?

Yes - it is for the EGR valve. (exhaust gas recirculation to theoretically cut down on emissions)

Yes I looked at yours. Unfortunately I don't have a welder at the moment.

I saw this advert in ebay
http://pages.ebay.com/link/?nav=item.vi ... 1404683367" onclick="window.open(this.href);return false;
And was thinking of contacting them to see what kind of price I'd be looking at for them to make me up the exhaust pipe in 55mm with a silencer.

Mine doesn't have an egr valve

I don't suppose you know the part number for yours?
A guy on my road breaks VWs and he'd keep an eye out for one for me. And I could easily blank off the egr port.

I'll take a look tomorrow - I've got to dive in the engine bay tomorrow anyway as my starter solenoid is playing up, I'll take some pics and look for numbers.
I think that most people have blanked off the egr port - I considered it as there was loads of crap inside the inlet manifold when I got it but decided to keep it as VW intended to see how it behaved.

Can't get a decent photo and the numbers can't be distinguished as obscured by the inlet manifold but it looks the same as the top one of the two in the picture above.