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Thread: TDI Exhaust repair

  1. #1
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    TDI Exhaust repair

    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

    Click image for larger version. 

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    Paul (Depronman)
    1.4 TDI 2001 287,347 miles and still going strong

  2. 6 users that liked this post:

    67boris (13-07-2017), cheechy (14-07-2017), Darren C (13-07-2017), imranshariff (13-07-2017), Sarge (13-07-2017), sco (13-07-2017)

  3. #2
    Had the same problem on my A2 Tdi, and although i bought the same part (Stainless steel flexi pipe) I had my local garage fitted mine.
    Even the mechanic was impressed by the quality of the pipe and he originally quoted me over 300 just to replace the whole exhaust i ended up paying just 70 all in!
    http://www.ebay.co.uk/itm/131759495260 is the ebay part number.

  4. #3
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    DP and CAT fitted back to the car, all is well again and quiet
    I do believe the last owner of this A2 TDI was quoted 680 for the Exhaust replacement, so feeling a little smug that I have it sorted for 35 and a couple of evening work.
    Paul (Depronman)
    1.4 TDI 2001 287,347 miles and still going strong

  5. #4
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    Quote Originally Posted by depronman View Post
    DP and CAT fitted back to the car, all is well again and quiet
    I do believe the last owner of this A2 TDI was quoted 680 for the Exhaust replacement, so feeling a little smug that I have it sorted for 35 and a couple of evening work.
    Is this the fella from London that I told he could probably manage this cheaper than that quote and his mechanic must be a robber?


    Sent from my iPhone using Tapatalk

  6. #5
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    yep that's the one

    I got myself a very nice 2001 plate TDI with 151K on the clock, a LOAD of service history, a genuine spare wheel with carrier/bracket, working OpenSky and new Aero wiper.
    All in all in really very nice condition and even came with 3/4 tank of fuel
    Drove back from London without any issues

    Exhaust now sorted, headlamp bulb replaced and the boot lock fixed.
    Still to do the wheels which need a total refurb and repaint the front and rear bumpers

    It will then be a really nice TDI
    Paul (Depronman)
    1.4 TDI 2001 287,347 miles and still going strong

  7. #6
    Join Date
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    Quote Originally Posted by depronman View Post
    yep that's the one

    I got myself a very nice 2001 plate TDI with 151K on the clock, a LOAD of service history, a genuine spare wheel with carrier/bracket, working OpenSky and new Aero wiper.
    All in all in really very nice condition and even came with 3/4 tank of fuel
    Drove back from London without any issues

    Exhaust now sorted, headlamp bulb replaced and the boot lock fixed.
    Still to do the wheels which need a total refurb and repaint the front and rear bumpers

    It will then be a really nice TDI
    Much of that repair work is impossible to the average person - your gifts allow you to have a really nice TDi. Most peeps shy away from welding.

    I remember reading the manual and seeing that a headlight bulb change says 'go to dealership' - so it's no surprise people see a holed exhaust as a bit much to DIY.

    I spent two hours last night trying to remount a tyre! Some things are best left to those with tools and SKILLZ!


    Sent from my iPad using Tapatalk

  8. #7
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    Even I don't remove and remount tyres, the local tyre shop as monkeys that do that for me for a few peanuts

    You are totally correct a lot of people are put off by a car that needs some relatively minor work, take it to a garage to get it done and the costs soon mount up, but if you are able to tackle the jobs yourself then you can get a really nice car for not a lot of money
    Paul (Depronman)
    1.4 TDI 2001 287,347 miles and still going strong

  9. Users that liked this post:

    Pinkythelabrat (14-07-2017)

  10. #8
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    Ps. Please paint that exhaust. The rusty picture gives me Heebies every time I see it!

    I'm more put off by the lack of driveway or garage. All repairs done at the side of a busy road adds a certain air of excitement. It's also my daily driver so my 70 mile round trip demands I finish anything I start.

    I look in awe (and jealousy) on everyone who takes on these momentous jobs as well as those that you deem commonplace and 'easy' - they are not!


    Sent from my iPhone using Tapatalk

  11. #9
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    Quote Originally Posted by Pinkythelabrat View Post
    Ps. Please paint that exhaust. The rusty picture gives me Heebies every time I see it!

    I'm more put off by the lack of driveway or garage. All repairs done at the side of a busy road adds a certain air of excitement. It's also my daily driver so my 70 mile round trip demands I finish anything I start.

    I look in awe (and jealousy) on everyone who takes on these momentous jobs as well as those that you deem commonplace and 'easy' - they are not!


    Sent from my iPhone using Tapatalk
    Exhaust and cat were treated to a nice couple of cotes of aluminium heat resistant spray paint. Lidl finest


    Sent from my iPhone using Tapatalk
    Paul (Depronman)
    1.4 TDI 2001 287,347 miles and still going strong

  12. Users that liked this post:

    Pinkythelabrat (14-07-2017)

  13. #10
    Out of interest do you know what metal the exhaust hangers are made of? Regards, M

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