166 V6 Exhaust fitting snag.

Well a dry day today...So time to get Imasaf exhaust out of the interior of the car and into situ where it should be.So I can drive Lacey again.

The imtermediate pipe where temp wrap was used was OK but the pipe had failed at the joint with the cat.

The back box looked ok so I thought that I would just replace the intermediate pipe.

NUTS AND BOLTS ALL SEIZED AND RUSTED.

So with a wee hacksaw I cut the centre of bolts.Expected the old bolts to tap out...No chance..They are welded in situ and a welder has not been near them.AARGH.

So off came the back box as I couldn't get the old bolt out of clamp.

I have pics which I'll attach when my old arms are better.

The heat shield had dropped on the back exhaust it had came off at the 3 bolt on washers.The recycle bin had just ben emptied BUT a can of Pespi out of the fridge and the empty tin does the trick...You guess which is the best of the 3 when I get pics uploaded .I know the one I like.
Now have the 2 rear exhaust sections in situ BUT I cant get the remainder of the bolts out of the bracket at the rear of the cat.

Was going to do the cat as well but the cat is fine and to remove the bolts out of the front of the cat would be just as exhausting.

Tried heat ,tried a ball joint seperator and a tap with a hammer.No joy..
Next dry day I'll try to drill them out.

Anyone else experienced this and if so how did you resolve.


Pics to follow to assist anyone else tackling it themselves.
Pomeo

Pomeo,
sorry to hear this. There must be people around who have had new central sections fitted though.

I will delay having a new cat back system until we hear the answer.

Mike

Pomeo sorry to hear the problem with rusty bolts / nuts is there no way of using a penetrating oil as opposed to cutting them. Is it just Alfa's or all cars as they age get rust in their bolts etc.

My specialist had to manufacture a new centre bracket. I don't know details though.

What a diffence a day makes.
Rested yesterday and today after 3 broken drill bits and 2 recharges of cordless battery pack.....Findus....Success on a plate.


I am really back where I was going to start from.

Original idea replace the 2 rear sections.

Got whole system so I think what the H.Fit whole system.

With the difficulty in wrong front pipes supplied was going to do cat and 2 rear bits.
.
Plan changed Now just the 2 rear bits.

The front bolts on the cat look as difficult to get out as the bolts at the rear of the cat.

God knows what the downpipes will be like when I go to do it.

The cat and downpipes are sound so possibly just wait until they go and needs must.

Quite chuffed now hot shower and off to the visiting.

Pics later if I can still do it.Last time the card went faulty and lost all the pictures.

Pomeo ( Now dancing on the ceiling)

Thats the pleasure wonder what the next pain will be.

Pomeo,
Congratulations, looking forward to the pics.

Mike

Pomeo so you got there in the end, i wouldn't spend time changing anything until you really need to, even if you are a bit handy and DIY all makes sense to me.

A few for a start.

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that was the easy bit.

Pomeo

the hard bit.

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note i even had to use my prayer mat. (I dont think i ws the only 1 yesterday)
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job done. Well part done.

On the test drive I am getting a rattly sound around 1500 to 2000 revs above and below no noise.....Water Pump?

Perhaps just needing a wee run....time will tell when I can locate it.


Thanks for your support guys I was about to throw in the towel yesterday But my boy had sharp drills....Being a joiner he only uses the wood bits out all the kits.

Pomeo

Well done mate. Just one q...where did u get the system and how much?

cheers
Tim

Originally Posted by alfasudsprint

Well done mate. Just one q...where did u get the system and how much?

cheers
Tim

Hi Tim
Sorry about the delay in responding but Laceys Mot is due and needs both front lower arns done and the brakes.i ordered all the parts about a month ago and when I went to fit it they had supplied the wrong discs in the right box.When I did Pomeos front lower arm it only took 1 hour start to finish.Laceys was a nightmare took the whole day.

Re the exhaust I won it on ebay for £109 and £30 carriage....BUT A Big But the deal went cold and after a dispute and assistance from a helpful chap a full exhaust system arrived cat and all .But the 2 front pipes a double and a single were for a 164.The 2 rear sections were Imasaf as pictured above and is good quality.

i was going to get them from a german ebay shop, both sections were for £200 all in but due my delay in getting it and the rising EURO they are getting dearer but not as dear as some suppliers here.I was going to £200 for the german imasaf and reckoned the ebay auction was worth a gamble...It paid off but was a lot of grief.

Pomeo

Yes Grief but not as much as doing the brakes and front bottom swinging arms for Laceys Mot on the 19th.

Ordered the discs last month and were in the box until fitting a couple of days ago.The swing arms I have had for some time.

I started taking pictures 1 stage at a time to assist others.Pomeos OSF bottom arm was a dawdle.I thought Laceys would be the same...Fraid not.

I thought I would make task easier by removing the brake disc and giving easy access for the ball joint seperator.

First couple of pics and easy

Note monoblock bricks ready to hold caliper.
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Bolts out and off the caliper comes
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Caliper sitting on bricks
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Brake disc off to gie easy access to bottom ball joint
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Bottom ball joint and boy was it in tight.
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This is the penutimate picture just before I threw in the towel and of course a few wee swear words.
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Then realised the brake discs were similar on the outside but different on the inside.
The box was for an Alfa 166 BUT found out later that the discs were for a Merc....AARGH

NEVER JUDGE A CAN BY ITS WRAPPER.

This was my metal block....downhill after there took me the whole day to comple job and I had to replace the old discs as I now need to wait until they sort the mess out.


Pomeo

Last picturs showing the wrong discs...AARGH

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Now just need new discs and good weather again.


Decidedly dodgy combination.

Then I have to do the other side which needs a sticky boot tooo.

And I was sure (On past performance) I'd have both sides done in a morning.

Pomeo

If its only the front brakes that are the wrong size I can give you my front brake parts so that you can get her through the MOT.

Originally Posted by stu_the_flat

If its only the front brakes that are the wrong size I can give you my front brake parts so that you can get her through the MOT.

Thanks Stuart but I think it will pass with the ones it has.

Did you get the drilled ones...Those were the ones I was going for from Buypartsby until I saw these ones.


Ive not checked the back ones yet but they look similar....But then agin so did the front ones.


AND NO I AM NOT GOING TO MANCHESTER BUT STU THE BLU IS...ILL WATCH IT ON HIS BIG TELLY.....ANYWAY LOOKS AS THO THE WONDERFULL WELL ARE IN EUROPE NEXT SEASON ....I'LL CELEBRATE WITH A BIG CURRY TONIGHT


Pomeo

Sadly no. Money is getting really bad at the moment and running that bloody puma is a nightmare.

I've had to do the Timing belt, Clutch and the heater broke (fixed myself). Now all it need doing is the lower wishbones and rocker gasket. I hope to be able do do these things my self (hence why I would like you to show me how to work underneath a car safely!) . Oh and one of the tyres is down to 3mm

So I've had to go with the £20 a disc the buy parts buy offer. They are from a company called Scandinavian braking systems They look OK and due to my chavvy wheels I'll be able to tell very quickly if there not up to the job. I wish had bought better ones but Beggars can't be choosers.

COME ON FUNDING! Once I'm on a longer term contract things should be a lot better. AT the minute I've only got a job until september!

I'm glad that Rangers are doing well I was round at a freinds house of friday night He lives right accross the street from the Orange hall! have to say it was one of the most scary places I have laid my eyes on!

Well it was worth doing the exhaust.(And the sticky boot yesterday) Lacey sailed her MOT with just 2 advisory's

An advisory on the bottom ball joint where I did the sticky boot yesterday....Did the other side as above but left this side just in case sticky boot didn't work and I had to strip it down to put on an original boot.Now bottom ball joint arm will be done when new brake discs arrive.

The other advisory was on drop link at rear...So now off to source the parts and get both sides done ASAP.

Pomeo

New discs arrived today.
A sealed box...Oh ya beauty...
Openned the box...not even box 13 (Take you pick fans only).........AAARGH the same merc discs inside well not the same but similar...A phone call to the seller again...Expalained.he said he'd check....An hour later was the tele call I expected...Yep they openned all the 166 boxes and every one had the merc discs in them....Problem at manufacturers...Correct ones should arrive tuesday.....Am I the only 1 to get this grief ?


Pomeo

Fine thread , will be useful at some time to fit new exhaust.

About the brakes: ordered a set of Brembo discs and ATE pads - it was like i went to get original AR parts but half the price (same manufcturer).

Originally Posted by Pomeo

Hi Tim
when I went to fit it they had supplied the wrong discs in the right box.Pomeo

Similar thing happened to me when my 166 went in for it's water pump and belt. The belt was for a 2 litre T Spark. Box was wrongly marked up.