Exhaust change time... :(

[GazHyde]

Oh well, guess it was due. Not sure if you all remember but when we needed to remove the exhaust for the sub frame refresh the flanges on the exhaust coupling between the cats and the rear section were in bad condition. Picture to enlighten those who don't

We finished the sub frame refresh and put it back together and all was good until we needed to remove the exhaust again to change the clutch. The bolts had corroded badly which seems to have caused further degradation on the flanges. We managed to fit new bolts, but it didn't really seem that they were quite going to hold.

So tonight the dreaded exhaust blowing started, and has now got worse. Looks like I'll be heading down the exhaust centres tomorrow to see what can be recovered from the situation. May even just cut my losses and head down to Long Life in Basinstoke and see if they can replace the whole system including the cats. Been wanting to change the exhaust note for a while, so maybe this is the time...

 

[t-tony]

Maybe now's the time Gaz as you say. Hope it don't hit the pocket too hard mate, and hope the sound is worth it.

Tony.

 

[Dino D]

Get a nice sounding one, makes the car for me, glorious engines these.
I had a long life on a Honda Prelude VTI and when I found too loud after a week they added an extra box at no extra cost. They have nice tailpieces too.

It always hurts when having to spend money but when fixing something presents a chance to upgrade and see/feel the difference at least it's satisfying. Exhaust rates right up there for satisfaction (unlike cooling system stuff that just sits there under the bonnet, yes very important but not as much fun to had from upgrading a water pump!)

 

[Grumps]

Maybe now's the time Gaz as you say. Hope it don't hit the pocket too hard mate, and hope the sound is worth it.

Tony.

He will if he gets a longlife! Will Connor's 2.8 be the same fitment @GazHyde? Maybe worth a nosey, pretty sure he's still after selling his?

 

[GazHyde]

Not sure if the fitment is the same, but the problem I have is time as it needs sorting before Sunday's cruise!

 

[GazHyde]

Just got off the phone with Long Life, really helpful chap but this wasn't the answer I was looking for particularly...

I was hoping to change over to Sport cats but the cats are actually a part of the exhaust manifolds on the 2.0, 2.2 & 3.0 .

To get around the issue of the flanges being rubbish, they would cut off the existing flange on the cat section and weld on new ones. They can then build a stainless system back from that. Been quoted £360 all in for cat back which seems incredibly good value.

Can choose my level of "loud" but as he said, the louder you go the more chance of droning...

 

[GazHyde]

OK, been doing some thinking as to whether I can retrofit different exhaust manifolds. I've come up with some off eBay which are listed as M52/M54 front and back flank exhaust manifolds. As you can see they don't have cats. The description says

M52/M54 6 cylinder petrols from 09/1998 -2003
Back flank exhaust manifold
Part number 11621706539
This part is also used on some early e46 3 series and Z3 with M52 engines fitted.

Looking at the part number they list on BMWFans it suggests it should fit the 3.0 M54 engine. I can't think of any reason why if that's the case, it won't fit the 2.2? I could switch the manifolds out, and then have the rest of the exhaust made up from there including those lovely sports cats I've been craving for so long...

Bit of a leap of faith I'd guess... anyone care to prove my idiocy?

 

[Brian H]

No reason why it would not work really, this manifold was used up until Sept 00, from that point the cat was used integrated in the down-pipe. As long as the heads stayed the same, it is a bolt on item

Forgive my ignorance but what would a sports cat do? Better sound? Better exhaust flow?

 

[Brian H]

Just a though Gary, the standard manifold has heat shields attached, the not cat unit does not, not sure if this creates an issue but some form of heat-shield or manifold wrap may be worth a thought.

 

[hard top]

Forgive my ignorance but what would a sports cat do? Better sound? Better exhaust flow?

As far as I know, better flow rate, lighter weight and on larger engines they reckon gains from 4 to 10bhp but you wont notice much on smaller engines.

 

[zedonist]

My thoughts, if you are doing something significant to the induction with includes head work, then sports cats are beneficial, I don't see what the benefit will be power wise without the up front work and engine mapping, so would be spending money for money sake. Cat Back exhaust yes, as it is a cheaper alternative than buying stock, and will last longer.

 

[GazHyde]

Thanks Brian, I think that makes me feel a little better about it as a solution. Made a mental note about the heat implications!

@zedonist - the overall "plan" would be to sort out a better air intake, better free flowing exhaust and engine remap. Just thinking that it's a good overall solution knowing there isn't really that much more that I can do with the engine without cracking it open... I know the 2.2 isn't ever going to make huge gains power wise, but this should be a reasonable attempt at making the best of things - well in my mind anyway!

 

[zedonist]

I agree Gaz, you know me, if it can be done do it, but the one thing i have always baulked at is sports cats, I think i would look at exhaust wrap (Keeps the gases warmer and faster moving, also the cat works more efficent) before going that route as in my mind a cat whether sport or OEM is still restrictive, the sport one is just less so and the ideal would be no cat all, so the cost for me just really outweighs the gain.

But what you will find when you change to a stainless free flowing exhaust and an induction kit is that the car will run worse, so a remap is needed, this was never the case on the old carb cars, you just changed the jets, adjusted the fuel flow and timing and bob was your smiling uncle.

 

[GazHyde]

Cheers for your balanced opinion Rich. I think for now I'll book it in to Long Life and get them the cut and weld on a new flange, then build a new cat back system. I can always revisit it later on when I have more time/cash!

Need to find somewhere to try in the short term to try and stop the system from blowing, and hopefully get me through the south downs cruise at the weekend.

 

[GazHyde]

Cat back stainless system booked for Monday 9am. Should take about 3 hours to complete. I'll see if they will let me take some piccies

Guess there will be a noise video posted around mid afternoon

 

[Aceman]

Make sure you choose a good set of pipes as I think that does make the rear end look better.

 

[GazHyde]

I think they have a selection you can choose from there, so will make sure I have something which looks as good as she deserves!

 

[M666BMG]

Make sure you choose a good set of pipes as I think that does make the rear end look better.

I'm not impressed with your rear end gaz

 

[GazHyde]

That explains the blowing then...

 

[Grumps]

Think that's known as knackered Gaz!