1.9 DG exhaust options

[Whitevanman]

Exhaust failed MoT on 4 counts
1) Major leak of gasses
2) Not adequately supported
3) Noise in excess of that emitted by a similar vehicle with standard silencer in average condition.
4) Unable to test emissions

Its fairly clear that existing exhaust is junk so looking at options from various suppliers. Was going to go for the cheapest route but then found this

http://www.vwspeedshop.com/product.php?productid=16733" onclick="window.open(this.href);return false;

The wbx engines get a lot of bad press but a free flowing exhaust like this, combined with a free flowing intake could make for a nice upgrade.

Has anyone tried this exhaust?

[CovKid]

Type 'vwspeedshop' in search box on here - all you need to know.

[Whitevanman]

Thanks - lots of good info. Will go for the vwspeedshop option if they can answer a couple of questions tomorrow.
1) Is there a performance change
2) how robust is an exhaust system that is basically hanging off the head studs

[ghost123uk]

2) Not adequately supported

What was that bit about ?

Is yours the early type (2 inlets on the silencer) or later (1 inlet at the left hand end) ?

If the early type, then there was an option for some brackets that support the silencer, but most vans (iirc) don't have them and it is not an MOT failure. The later type (being heavier) does have important mounting brackets.

[Whitevanman]

Its the later type and to be honest the complete exhaust is in a shocking condition with all the mounts rusted through, holes in the front piping and completely shot silencer. Current problem is with the exhaust studs into the head. Only two of 8 came out. I could tell by looking at some of them that they would break to exhaust was removed with a grinder not a spanner! At least that leaves something to go at rather than sheering studs flush with the heads. Currently soaking with plus gas, will then try with heat and mole grips, then welding a nut on. If that doesn't work i think its head off or dropping the engine to drill them out. If I go to these lengths I should refurbish as I go, perhaps even improve things, perhaps a subie motor

[ghost123uk]

Don't take the heads of in situ as you are very likely to disturb the wet liner seals and replacing them ain't a job to do in situ. If you have to, drop the engine to work on the studs. Swine isn't it

[Whitevanman]

Two of the studs now sheared flush with the head - nightmare. Despite efforts with plus gas, heat and welding nuts to the broken stud I am defeated and they will need to be drilled out. Access is not too bad but will need to lower the engine to get in square with a drill.

[Whitevanman]

It has taken 6 months to find a day spare to get my exhaust sorted.

In the end I lowered the engine and removed the half shafts to drill out sheered exhaust studs. Not as bad as it sounds and was going well until my stud extractor snapped in the hole making one stud even harder to get out By the time I'd gouged it out the thread was knackered so had to heli-coil that one but it seems to be holding. All done outside on the drive but would have been much easier with a ramp.

Exhaust from VWspeedshop fitted well but bottom of rear valance needed to be pushed up slightly for adequate clearance. Exhaust sounds good but not driven it yet so not sure if performance will change.

http://www.vwspeedshop.com/product.php? ... 476&page=1" onclick="window.open(this.href);return false;

As my neighbor pointed out its a very expensive and shiny looking exhaust for a very tired looking van.

Thanks for the advice it made the job easier.

Mark

[ghost123uk]

Thanks for posting the "follow up" Mark, so many folks forget to do it !