1.9 Exhaust System

[The Hairy Camper]

So i'm slowly preparing a 1.9 1Y engine to replace my 1.7KY (with a tired alternator)

I was just enquiring about a JX Alternator when the kind fellow offered me the exhaust system from his 1.6td also. Is this a good system for a 1.9 engine?

My current exhaust system is from a 1.6 (non turbo)! Is it a straight forward swap?

Pics of the JX Exhaust:



Cheers!

[The Hairy Camper]

So looking through the forum, it seems that the JX exhaust manifold may be different to the CS/KY manifold. Can anyone confirm this?

Also, if the JX exhaust manifold is different/bigger, will it fit a 1Y engine nicely? I'm getting lost now

Cheers.

[Oldiebut goodie]

What is wrong with making the exhaust system to suit the 1Y manifold? That way you will not be choking the gas flow.

[The Hairy Camper]

Hey Oldie, is that what you did? I thought the 1Y manifold was to big to fit in the engine bay?

[Oldiebut goodie]

It is the inlet manifold that will hit - have you read the thread https://club8090.co.uk/forum/viewtopic.php?f=12&t=107034

[The Hairy Camper]

It is the inlet manifold that will hit - have you read the thread https://club8090.co.uk/forum/viewtopic.php?f=12&t=107034

I'm probably going to sound stupid here, but is the inlet manifold different from the exhaust manifold?

Yes i've read though that guide a couple of times bud.

[Oldiebut goodie]

You can see the 1Y inlet manifold here on the left - aluminium, the exhaust manifold is rusty cast iron underneath it.

[The Hairy Camper]

Much appreciated Oldie, that is a nice shiny new looking alternator your engine

Did you use a modified 1.6/1.7 exhaust manifold?

[Oldiebut goodie]

No! Used the 1Y one otherwise you will choke the exhaust. People have used them but I prefer to allow the engine to breathe as VW designed it and stuck to all 1Y in and out.
It is all detailed in the 1.6 to 1Y thread.

[colinthefox]

My opinion (which differs from OBGs) is that there isn't much wrong with re-using both the inlet and exhaust manifolds straight from your old KY engine.

The inlet or exhaust from a JX is not really suitable for what you want, as it was designed for a turbo.

In the end it all depends on what you want to achieve.

The advantages of OBGs setup are that you will get a small amount more power at high revs due to marginally better gas flow. The disadvantage is that it will be considerably noisier due to the cone type filter in the engine bay without noise attenuation. There may also be a risk of water getting breathed into the engine due to the position of the air intake. You will need to get a custom exhaust pipe made up from the exhaust manifold to the silencer.

The advantages of re-using your existing manifolds from the KY is that the engine will be much quieter, (as long as the original systems were complete and leakproof) and that no special parts need to be made. Against that, you will have a slight reduction in power at high revs (although I can't say I've ever noticed that) It is also advisable to slightly modify the fixing holes of the exhaust bracket and adjust the fitting of the downpipe into the silencer, as the 1Y engine is a smidge taller than the KY.

For more information have a look at this thread http://www.brick-yard.co.uk/forum/1-6cs ... KW=#413096" onclick="window.open(this.href);return false; which has sections on inlet and exhaust systems. It's about the AEF engine, but that is so similar to your 1Y that it makes no difference.

[Oldiebut goodie]

The disadvantage is that it will be considerably noisier due to the cone type filter in the engine bay without noise attenuation. There may also be a risk of water getting breathed into the engine due to the position of the air intake.

The intake is ducted down following the original snorkel route - that pic is upon first installation before that was done.

[The Hairy Camper]

No! Used the 1Y one otherwise you will choke the exhaust. People have used them but I prefer to allow the engine to breathe as VW designed it and stuck to all 1Y in and out.
It is all detailed in the 1.6 to 1Y thread.

Cheers OBG

My opinion (which differs from OBGs) is that there isn't much wrong with re-using both the inlet and exhaust manifolds straight from your old KY engine.

The inlet or exhaust from a JX is not really suitable for what you want, as it was designed for a turbo.

In the end it all depends on what you want to achieve.

The advantages of OBGs setup are that you will get a small amount more power at high revs due to marginally better gas flow. The disadvantage is that it will be considerably noisier due to the cone type filter in the engine bay without noise attenuation. There may also be a risk of water getting breathed into the engine due to the position of the air intake. You will need to get a custom exhaust pipe made up from the exhaust manifold to the silencer.

The advantages of re-using your existing manifolds from the KY is that the engine will be much quieter, (as long as the original systems were complete and leakproof) and that no special parts need to be made. Against that, you will have a slight reduction in power at high revs (although I can't say I've ever noticed that) It is also advisable to slightly modify the fixing holes of the exhaust bracket and adjust the fitting of the downpipe into the silencer, as the 1Y engine is a smidge taller than the KY.

For more information have a look at this thread http://www.brick-yard.co.uk/forum/1-6cs ... KW=#413096" onclick="window.open(this.href);return false; which has sections on inlet and exhaust systems. It's about the AEF engine, but that is so similar to your 1Y that it makes no difference.

Thanks Colin, i found your 1.6-AEF guide a while back, really good read so thank you. I always wondered if i needed to drill a new dip stick hole on the 1Y like you did with the AEF? I don't think i'd trust myself doing that

Thanks for all your info here, is the CS/KY exhaust manifold definitely better than the JX? I assumed the bigger JX exhaust pipe would allow better air flow? Apparently there is a egr people seem to have issues with??

[colinthefox]

I always wondered if i needed to drill a new dip stick hole on the 1Y like you did with the AEF?

I think the 1Y dipstick is in the right place but the hole may be too big for the KY dipstick and needs some kind of different seal. That's the limit of my knowledge. Perhaps someone else can help.

Is the CS/KY exhaust manifold definitely better than the JX? I assumed the bigger JX exhaust pipe would allow better air flow? Apparently there is a egr people seem to have issues with??

You can use the KY/CS manifolds complete without modification. The JX exhaust pipe would need a different downpipe from the manifold to the silencer box if you decided to use the JX silencer. The JX pipe is indeed bigger. The turbo on the JX needs larger pipe to allow the exhaust gasses which have expanded in the turbo to flow easily, or the turbo won't work properly. So the JX pipe would allow better gas flow. The good news is that unlike a petrol engine, or a turbo diesel, a normally aspirated diesel isn't too fussy about this. (the technical reasons would clog up this thread, so I won't go into them here, but I'm happy to explain in a different thread if anyone is interested.)

The KY/CS engines don't use exhaust gas recirculation (EGR), so this wouldn't be an issue if you use the KY/CS manifolds, and this wouldn't affect the operation of the 1Y at all. If you use the 1Y manifolds from an engine with EGR, there is an extra flange on both the inlet and exhaust manifolds which you would simply blank off using a flat metal plate, gasket and a couple of nuts/bolts/studs. EGR simply reduces the NOX emissions, and you don't have to keep it.

[Oldiebut goodie]

I always wondered if i needed to drill a new dip stick hole on the 1Y like you did with the AEF?

I think the 1Y dipstick is in the right place but the hole may be too big for the KY dipstick and needs some kind of different seal. That's the limit of my knowledge. Perhaps someone else can help.

It is all in the thread that you have read! Very easy solution. No drilling.

[The Hairy Camper]

Cheers Colin, appreciate you going into depth.

The JX exhaust seemed like a better option, but if the 1.6 system functions almost just as well, it's probably not worth it. Especially if your AEF has functioned fine this long without exhaust issues.

If i feel like fabricating an exhaust pipe/manifold in the future, i may look into it more then.