Standard exhaust problems - Alfa Romeo Forum
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Thumbs Down Standard exhaust problems

I daily drive my 4C Spider since September 2015.

In December 2015 the standard exhaust was replaced in a recall campaign (camp 5939).

In April 2017 at 22000 km, my standard exhaust was replaced again under warranty by the dealer. The Alfa Romeo logo imprint on the muffler was opening up.


Now at 35500 km and 4 months out of warranty, the same problem has reappeared.


Alfa Romeo is willing to provide a new standard exhaust, but I have to pay for labour myself.

The issue is not having to pay for labour. It's the offered replacement of a faulty low quality part with the same low quality part which bothers me. Now I probably will end up having the same problem in a years’ time.
Alfa Romeo (FCA) customercare is of no use. Alfa Romeo (FCA) hides behind an anonymous call center and won't speak to me directly. No way, in my opinion, to deal with their clients. No heart and soul here, just protocol.

Anyone on the forum experienced any problem with the standard exhaust?

2015 4C Spider
2010 Giulietta QV
1991 Spider

2006 159 SW
1998 146 1.6
1986 33 QV
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Some of the other parts in the photo don't look all that healthy either? But then it's the same for any car of that age. The exhaust appears to be weakened by the embossing and then the form allowing condensation to sit there. Is it a separate disc or an embossed logo?
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Originally Posted by cue2 View Post
Some of the other parts in the photo don't look all that healthy either? But then it's the same for any car of that age. The exhaust appears to be weakened by the embossing and then the form allowing condensation to sit there. Is it a separate disc or an embossed logo?
You are right, it corroded at the edge of the embossed logo.
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Quote:
Originally Posted by Haha View Post
I daily drive my 4C Spider since September 2015.

In December 2015 the standard exhaust was replaced in a recall campaign (camp 5939).

In April 2017 at 22000 km, my standard exhaust was replaced again under warranty by the dealer. The Alfa Romeo logo imprint on the muffler was opening up.


Now at 35500 km and 4 months out of warranty, the same problem has reappeared.


Alfa Romeo is willing to provide a new standard exhaust, but I have to pay for labour myself.

The issue is not having to pay for labour. It's the offered replacement of a faulty low quality part with the same low quality part which bothers me. Now I probably will end up having the same problem in a years’ time.
Alfa Romeo (FCA) customercare is of no use. Alfa Romeo (FCA) hides behind an anonymous call center and won't speak to me directly. No way, in my opinion, to deal with their clients. No heart and soul here, just protocol.

Anyone on the forum experienced any problem with the standard exhaust?

I have the race exhaust.
The car only has 13000 km.
Gonna have a look if there is a logo on it too.
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Rubbish quality parts, shame to find them on such a good car. The race exhaust doesn't suffer the same issue but they're a bit more difficult to live with. Perhaps ask if FCA will post the parts to you, then you can put them on ebay and get rid of them, raise a bit of cash and get something decent quality made up by an exhaust builder.

Find yourself a good independent Alfa specialist with 4C experience and you'll never need to deal with FCA again.
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Originally Posted by Giulietta 64 View Post
I have the race exhaust.
The car only has 13000 km.
Gonna have a look if there is a logo on it too.
The race exhaust has only tubing, no muffler, and no logo, and use of better material. You're probably safe.
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Originally Posted by Pud237 View Post
Rubbish quality parts, shame to find them on such a good car. The race exhaust doesn't suffer the same issue but they're a bit more difficult to live with. Perhaps ask if FCA will post the parts to you, then you can put them on ebay and get rid of them, raise a bit of cash and get something decent quality made up by an exhaust builder.

Find yourself a good independent Alfa specialist with 4C experience and you'll never need to deal with FCA again.
You are probably right, but for a fairly new car in this price-range, Alfa Romeo could offer a better solution.
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It's ironic that the embossing of the metal ,to prove its a genuine part, is the bit that's caused the stresses in the mild steel which has then rusted right there. Mild steel has great properties if you don't want the booming of stainless steel and usually lasts years if you use it regularly for long enough trips to avoid condensation building up. Sounds like you do that.
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You are probably right, but for a fairly new car in this price-range, Alfa Romeo could offer a better solution.
They could, but I doubt they will. They've ended production now I believe, so more than likely they'll do what they always do, run down the inventory and start discontinuing stuff as soon as possible. I love FCA cars, but they don't do much to try and keep them on the road; parts availability is much much better for German stuff, I'm currently doing up a Mk2 Golf and its amazing how much you can still buy direct from the main dealer and get within 24hrs, good prices too.

I guess what you could do is find a welder and get a plate welded over the hole, but the skin itself is probably galvanised so will be a pain to weld to.

If someone brings us a 4C we'll happily design a prototype exhaust system to suit, something which fits the design criteria of the original non-Race system. We've been looking to do it for ages but haven't been able to get a car when we've had time in our schedule.

Autolusso Penrith - UK's leading independent Alfa Romeo specialist with branches in Bedfordshire, Cumbria & Dorset

Wizard Exhaust systems available here

Tel: 01768 879 171
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They could, but I doubt they will. They've ended production now I believe, so more than likely they'll do what they always do, run down the inventory and start discontinuing stuff as soon as possible. I love FCA cars, but they don't do much to try and keep them on the road; parts availability is much much better for German stuff, I'm currently doing up a Mk2 Golf and its amazing how much you can still buy direct from the main dealer and get within 24hrs, good prices too.

I guess what you could do is find a welder and get a plate welded over the hole, but the skin itself is probably galvanised so will be a pain to weld to.

If someone brings us a 4C we'll happily design a prototype exhaust system to suit, something which fits the design criteria of the original non-Race system. We've been looking to do it for ages but haven't been able to get a car when we've had time in our schedule.
I can still get parts for my 1978 BMW100RS usually with a couple of days.

That's a very good offer of designing a proto exhaust that complies with design criteria.
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We're good with resonators, so can usually get a nice sound out of a turbo 4-pot without any boominess. Bit more difficult on a normally aspirated 4-pot. I doubt there's a 4C owner in the world who just wants it quiet, but most owners would prefer to drive down a motorway without getting their eardrums done in which is what the race exhaust does. Sounds like a happy medium is required.

We managed to get a Mito Cloverleaf sounding like this (no silencers, just one big resonator in the backbox) but no boominess either:

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Glad my incoming 4C Spider has the race exhaust option!
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Update: the new exhaust was installed today and doesn't have the embossed logo. It seems Alfa has had the same problem, more than they are willing to admit. Time will tell if it holds up. Happy to have the car back sooner then expected. Hard to forget the lack of customer care.
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All in all, thats good news.
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Originally Posted by Pud237 View Post
We're good with resonators, so can usually get a nice sound out of a turbo 4-pot without any boominess. Bit more difficult on a normally aspirated 4-pot. I doubt there's a 4C owner in the world who just wants it quiet, but most owners would prefer to drive down a motorway without getting their eardrums done in which is what the race exhaust does. Sounds like a happy medium is required.

We managed to get a Mito Cloverleaf sounding like this (no silencers, just one big resonator in the backbox) but no boominess either:

https://www.youtube.com/watch?v=7wrT_JxhVmU
If you’re still interested in a car for exhaust development let me know.
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If you’re still interested in a car for exhaust development let me know.
Yes we're still keen on doing a system for the 4C. Would you be able to get your car to Bicester, Oxfordshire for a few days?

If you prefer to email, my email address is the same as my username here @gmail.com
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It'a amazing that on cheap 156s and 147s they managed to make an exhaust system that in most cases has outlived the car. On an expensive 4C, they've managed to make something that lasts 2 years. It's not really progress...
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Hi all

I have a mito 1.4T. I added a full stainless steal downpipe and exhaust an aftermarket induction kit and stage 2 etuners software. Im pleased with the results and pushing 285nm at the moment.
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It seems a little bit unnecessary to produce an exhaust component with a complicated pressing of the Alfa logo on a part of the car that is never seen! Obviously the pressing has compromised the metal and caused it to fail.
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I thought the new replacements don’t have the pressing. For what it’s worth, the Alfaworks -Quicksilver has been on mine for three years now without any problem. Looks as new as the day it was installed.
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