Breathing....

[Grimsqueaker]

Has anyone modified the intake/exhaust systems on their 1.9D's in order to improve the flow in and out of the engine....

The intake on the Mk2 where it draws air from behind the grille is, tbh, bleedin 'orrible.... there isnt even a hole in the grille in front of the intake pipe, it has to rely on air coming across behind the grille from the other side..
Resistance in the intake system means the engine works harder to draw air in, which in turn saps power...
With this in mind I have removed the pipe from the front so that the flow is unrestricted into the filter housing, but can't help feeling there is much more that can be done.....

[Andre]

Not sure what your current set up is, but make sure it isnt drawing in warm air now from the engine, thats just as bad!

[Grimsqueaker]

The intake is on the opposite side of the filter box from the engine, but still far from ideal...

The next step will be to route colder air into it,

[adam3rdcanvey]

Grimsqueaker.....

Sounds like a great plan this one

I've always thought it was a bit of a design flaw myself.

The only modification I've made is a nice new exhaust back box from eurocarpart.... to get through MOT this year. Has a shorter and smaller diameter tailpipe though

Induction maybe another option if available....... I aint looked??

[lemsworld]

Adam I more than likely have the same back box for my Berlingo as had to get one for my MOT the original had a design flaw which made it sweat. Am interested in the outcome of this thread though as mine is the 53 plate 1.9 forte same as yours Grimsqueaker

Lliam

[Grimsqueaker]

Forced induction isn't a route I want to go down tbh, though I do like the idea of a supercharger

On the 'IN' side of the engine the limiting factors are the routing of the airways, and the max flow rate of the filter...

The ideal would be a cone or pancake filter bolted direct to the intake manifold with cold air ducted from the front grille, but factors such as EGR valve and MAF sensor prevent this...

On the exhaust side, any reduction in diameter from the original will add resistance, so is generally a bad thing... Increasing diameter can reduce resistance, but the engine will also be reliant on a degree of backpressure, so bigger isn't always better....

[adam3rdcanvey]

Ah.... so your plan is to re route intake from the blocked off section.... where to though? not a lot of space really..
Supercharger sounds awesome..... but i'm sure the insurance premium would kill my enthusiasm!!

My blingo sounds a lot better though after the exhaust change... had more holes than exhaust after the evil road salt season....

[Grimsqueaker]

decat pipes are around 45 quid on ebay, so that may be another way forward

[adam3rdcanvey]

yep sports cat / de cat shoud run well on our 1.9d
don't think there will be much bhp gain though, engine may run lean...
have seen this on an aquaintances vw caddy truck! worked well for him...
will try and get a phot

[Andre]

out of interest, does decatting decrease your mpg?