Technical Exhaust Replacement

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Technical Exhaust Replacement

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December - high pitch squealing. We secured it on better at the back box.

January - discovered hole in catalytic converter section where the pipe curls around and has a stick-out part where a bolt mounts it to the engine.

February - blissful ignorance, increasing sound from engine heard in car

March - as of yesterday, the car is roaring and it sounds as if metal is scraping along the ground when I accelerate at all! Really does sound like a tool box of heavy metal tools clashing together!!! I must sort this problem out.

Condition of the exhaust on my Panda: Unfortunately, the exhaust on my car has been subject to abuse from incompetent and/or lazy "mechanics". There is no flex joint piece, just a welded pipe. I suspect the main exhaust pipe going the length of the car is also just a welded job as it completely misses and does not join to the central mount points... NOR does the catalytic convertor part [which has developed a hole] with the bolt meet where it's supposed to.

The plan: I am considering biting the bullet and replacing the entire exhaust including catalytic convertor because,

1; we can't get it off without taking the whole exhaust out anyway given the fact most of it's welded together.
2; I'm told separating the cat from the front of the engine can be a tricky task given the huge temperatures bonding it together.. might need picked at to get off, leaving it in no shape to re-fit?
3; I'd like to restore the flex joint, it MUST be there for a reason... otherwise Fiat would surely have saved themselves the bother.
4; I would like the entire exhaust to be fitted CORRECTLY, taking advantage of ALL mounting points.


The only issue being the cost. I can source the exhaust parts for around £200 (see my attached screenshot) which since I don't have to pay for labour might actually not be so bad. I love getting things like this done but my car is 2005, 13 years old and I'm unsure if it's silly to fit an entire new exhaust system to an old car. Will I get use from it? My uncle who does a lot of the fixing maintains that the engine runs like a clock and the car will run forever with the way we've kept on top of maintaining it.

I understand that NORMALLY you'd just replace the single section with the issue but in my case it's all melted together in a mess...

And as a side question... what other benefits would a new exhaust bring? Surely the car would be quieter. Though I doubt it would run any better since this is essentially just a way of moving the fumes to the back?


So if you've read this far:

Should I replace the entire exhaust unit?
If so why / If not what should I do?
Any other tips?

Have I considered most of the parts here:
 

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Similar bodge to one I for the GF

Had to cut the old one off. Someone had welded the old one to the CAT and welded the back box onto the centre pipe.


I didn't need a CAT. Carefully cut off the pipe and filed the filed the welds off.

Got the parts from 3 different local motor factors

Back box £19.95 + VAT from CES
Centre pipe £26 inc from General Traffic
Exhaust manifold gasket £5.99 inc from Euro Car Parts.

Also need some gasket seal. I used some silicone seal from the pound shop.

The £26 included an extra clamp that wasn't included where as the back box came with a new clamp.
 
The back box was a completely different shape. Cant remember which way round it was. One had a square section the other oval. I was a bit concerned when collecting it, but it fitted just fine.


I did adjust it slightly so it was nice and flat under the car.

Did this by jamming some wood between the pipe and the rear beam then jacking under it. With all the speed bumps nowadays I wanted it to sit nice and flat. I doubt if it was done at the likes of kwikfit they would have bothered.
 
Should have put a warning in my first post

Only use silicone downstream of the O2 sensors or it will ruin them.


Not that there should need to use any higher up
 
The CAT Comes of easy. Just unbolt and pull forward. It's not the type of gasket that sticks

Seem to remember access to a couple of the nuts required Universal Joint on the socket and luckily I had the right length extensions
 
On mine, when the rear box rusted out - a frequent scene on the 169 - I just cut it off and used a plain pipe.

Mine's a diesel, and the little extra sound it made with no back box was pleasing, but not loud.
 
Just had to replace my back box as it fell off on the way home.
Rang up a local exhaust place just because it was 2 mins walk from my house and as working nights did not have time to fix myself.
Not sure i am allowed to post the name buy begins with a big K.
MY quote for a new back box fitted was £145.
Yes thats right £145.What a bunch of rip off b*******.

Found one on ebay for £26 inc postage but went with one for £30 and picked it up a few miles away the next day.
Quick and easy job to just cut off the old clamp and put on new one.
Only problem was during the day i had to bodge up the old exhaust to make it into work that night where i keep another car and that took nearly 2 hours in the rain.

£145, i would rather walk the 20 miles to work.
 
But you missed out on them telling you that your shock absorbers were knackered and you have only got a few miles left on those brake pads.....
 
But you missed out on them telling you that your shock absorbers were knackered and you have only got a few miles left on those brake pads.....

Haha Yeah thats true.
He did try and justify the price by saying it had a 3 year guarantee.
Doubt i have 3 years left and im sure my panda hasnt.
 
The original question was whether you should replace the whole exhaust?

The answer is 'why not'? £200 for the full deal isn't much and whilst that's probably a fair portion of the car's value, it's still cheaper than what you'd spend on any replacement car.

If you were on the mainland I'd suggest getting some used parts from breakers.
 
Yep that's a bad bodge. Thought mine was bad enough. A flex joint welded only on the bottom half and ditto at the rear box.

Done by a garage as well. Same rabbit poo welding though

But yours takes it to an new low
 
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