Club 80-90 Forums

Hi

completed a 1Y swap but using a turbo inlet manifold for the time being, the 1Y inlet mf wont fit due to hitting the bay wall.
has anyone modified it to fit, whats my next best option if it cant be made to fit

ta

 

It's worth checking if the inlet gasket is the same as used on other engines. I think I read about using a petrol inlet manifold somewhere. It's possible that the petrol 1.8 and 2.0l engines have the same type of inlet port layout.

The standard 1.6na diesel air box should fit also.

IIRC the 1.6D/TD head has an oval intake port, the 1.9's have a D-shaped, but are otherwise interchangable (they 'bolt-on'). So as said, perhaps you could use a T3 1.6 manifold for its engine-bay compatibility, and adjust the ports with a dieginder.
 

I used the 1.6 diesel manifold and air box as suggested above. The ports on the manifold can be ground and blended to nearly match the 1.9 head, ( but not exactly as there's not enough metal to do that) and I used a modified 1.6 gasket as it fitted better. If you use this setup, it will still just contact the left hand chassis box section, due to the engine being 10mm taller, so the wiring loom will have to be raised a bit, and the box section "modified" slightly with a hammer and lump of wood. It also helps to use any adjustment in the engine mounts to move the whole engine a smidge to the right. Once all this is done, it works OK. To keep the inlet quiet, it's important to connect the air box to the input snorkel  with the convoluted bellows or similar.