TDI Exhaust repair

depronman said:
The Exhaust was blowing at the flexi on the TDI that I bought a couple of weeks ago

Exhaust system is all in one piece from Audi and silly expensive.
Therefore a repair was in order.
A new custom made for the A2 TDI was bought for £25 and an 50mm pipe joiner.

Drop the exhaust off the turbo (4off nuts 12mm 6 point socket and a few long extensions latter), un clip the exhaust hanger rubbers near the CAT (2 off)
angle grinder to cut the pipe after the CAT, remove down pipe and CAT

cut the old flexi out, clean up the pipe ends with the angle grinder
trial fit the flexi to the DP and fit to car
trial fit CAT to flexi, check measurements for the rubber hangers, need to be vertical, mine where not. After some head scratching decided to turn the mounting bracket for the hanger rubbers around, this moves the hanger rubbers back about 1", alignment now perfect
Ensure the CAT sits level with the rubber hangers and exhaust DP on manifold square, then drill 3mm hole through flext and CAT pipe

Remove from A2 and mig weld the flexi to the DP and the CAT pipe

Job done all in £35 for the flexi and 50mm joiner

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Hi
Where about did you manage to fit the bar in after the extension can't for the life of me get the exhaust bolts off even after pentrating fluid.
Cheers Charles
 
Charles said:
Hi
Where about did you manage to fit the bar in after the extension can't for the life of me get the exhaust bolts off even after pentrating fluid.
Cheers Charles
Click to expand...
I like yourself couldn't get a breaker on every nut. One could only be accessed and turned with a 12mm ring spanner, then it came off a fraction of a turn at a time. The other three were loosened with a 1/4 drive socket and T bar then taken of with a robust 1/4 drive ratchet.
Two gave way to a wire brushing and good soak in penetrating oil, two required heating with oxy almost to the point of melting.
Edit, by any chance have you been talking to Tony Banks Exhausts in Leeds?
 
philward said:
I like yourself couldn't get a breaker on every nut. One could only be accessed and turned with a 12mm ring spanner, then it came off a fraction of a turn at a time. The other three were loosened with a 1/4 drive socket and T bar then taken of with a robust 1/4 drive ratchet.
Two gave way to a wire brushing and good soak in penetrating oil, two required heating with oxy almost to the point of melting.
Edit, by any chance have you been talking to Tony Banks Exhausts in Leeds?
Click to expand...
No I've been doing the cylinder head gasket on my new tdi 90 and am just struggling to remove the exhaust. This seemed like a good thread to get some help.
 
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