Bye, Bye Exhaust system...

2327 Views 27 Replies 8 Participants Last post by Kendrick, Jun 10, 2011

planner3357

Discussion Starter · Jun 8, 2011

On my morning commute to work this morning (30 miles), I decided to pass someone going too slow in the fast lane (Ontario, Canada plates)...when I hammered the gas the car shook and seemed to lose power and then gained it back. That's when I noticed the exhaust smell coming in through the a/c vents, and then noticed the loud sounding (awful sounding) exhaust, as well as the broken air sound echoing off of the cars and median to my left and right....

Haven't had a chance to look at it as I wear a suit to work...

What is the best/worst case scenario here? Can it be a DIY job?

This all after I just spent $1200 on front end work...I LOVE THIS CAR!

1 - 20 of 28 Posts

AlexGS

· #2 · Jun 8, 2011 (Edited)

Probably not as serious as you think... Maybe the increased torque of the engine rocked it on the mountings and broke the flange connection at the rear downpipe, or the flex coupling underneath. Since you say it's getting into the air intake I think it will be the downpipe behind the engine. You know this anyway but don't forget to check the engine mounts - if the engine moves around, a repair to the exhaust won't last long...

This is one of those times when I drive to an exhaust shop (one that has exciting custom projects on the go, not a 'fast fit' kind of place) and let them do their stuff. The way I look at it, they have a good selection of replacement/substitute parts, and better fabrication/welding skills than I have. On a newish car it's nice (and easy) to fit genuine replacement parts, and the 164 rear box is easy to change. But at the front of the system, where new parts are less readily available and old parts are rusty/broken, I prefer to get something made up and support local skills.

-Alex

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italcarnut

· #3 · Jun 8, 2011

Not sure what happened, but living here in Pittsburgh, rust is always an issue. If you need the center or rear muffler you can get a Bosal unit from Rock Auto, for less than 100 bucks each. Anything forward of that has a lot of stainless steel so hopefully those are OK.You will need to get under there and see what's up. These are easily DIY jobs. I always use stainless nuts and bolts and cover threads with antisieze compound. If you ever have to do the job again you will be grateful.

planner3357

Discussion Starter · #4 · Jun 8, 2011

Thanks for the advice guys. I took the car to a mechanic next door (non-Alfa). There is a threaded plug on the rear of the manifold that came out. He put a new one in and for $20.00 my exhaust sounds back to normal!

Although, he did mention the fact that my rear springs are broke...as I have known..really don't want to address that yet.

Kendrick

· #5 · Jun 9, 2011

Nice! I sometimes smell gas through my vents, does this have any correlation?

planner3357

Discussion Starter · #6 · Jun 9, 2011

Kendrick said:
Nice! I sometimes smell gas through my vents, does this have any correlation?

Check the hose clamps on the fuel rail. That's where I was getting it from. Gas will leak out of them if not fit with the OE sized hose and clamps.

Kendrick

· #7 · Jun 9, 2011

planner3357 said:
Check the hose clamps on the fuel rail. That's where I was getting it from. Gas will leak out of them if not fit with the OE sized hose and clamps.

Hmm, well i checked and there were no gas leaks from any lines or hoses. I smell it with my window closed, and it usually comes when i start the car and for driving for the first 3minutes, and ocassionally after that.

planner3357

Discussion Starter · #8 · Jun 9, 2011

You have to check those rails right after you start the car. There's a thread about this somewhere...think it's called fuel smell or something...there's a few things it could be other than the fuel rail. Does the trunk smell like gas?

Kendrick

· #9 · Jun 9, 2011

FOUND THE LEAK! It's those fuel hoses (2, left and right) inbetween the two valve covers and right under the intake manifold! It's leaking from both sides (end, cutoff) of both hoses. I remember changing the hoses a couple months ago because there were cracks in them, and now it's leaking from the end. Is it new clamps that i should be getting?

planner3357

Discussion Starter · #10 · Jun 9, 2011

Kendrick said:
FOUND THE LEAK! It's those fuel hoses (2, left and right) inbetween the two valve covers and right under the intake manifold! It's leaking from both sides (end, cutoff) of both hoses. I remember changing the hoses a couple months ago because there were cracks in them, and now it's leaking from the end. Is it new clamps that i should be getting?

My bet is that you have 7.99 mm hoses (5/16). Really, you need 7.5mm. This is what I went through. I had the 5/16 and couldn't get rid of the problem even double clamping.

I ordered the 7.5 mm from hiperformancestore.com and I haven't had a problem since.

You really don't want to risk the chance of an engine fire. Get it fixed ASAP.

Del

· #11 · Jun 9, 2011

By now, everyone with a 164 should have changed all the old OEM fuel hose over to new metric hose. Anyone not having done this is risking a fire due to leakage from the original lines. MY guess is that between the unusually high 164 engine compartment temps and 10% alcohol in USA gasoline, the OEM hose just hardens up and cracks/crumbles away.

Kendrick

· #12 · Jun 9, 2011

^ Thank you Del and Planner for the above replies.

Am i able to get the replacement hoses at a typical Kragen Autoparts store? If so, do i basically ask them if i could get a few feet of 7.5mm diameter length of new FUEL HOSE LINES? The problem was the hose being "too big/wide" and not my clamps?

It's been leaking pretty badly (i was too ignorant to notice it and take a look -_-), at about a couple drops every second from both sides of each line.

planner3357

Discussion Starter · #13 · Jun 9, 2011

The 7.5mm are usually only special items. Your best bet is to get them online somewhere like International Auto Parts.

Metric Fuel Hose by the Foot

You need 7.5mm high pressure fuel injector hoses with the necessary clamps.

I had to call them and make sure they put the clamps in there too.

Your problem was both the hoses and clamps were too big. Get a couple feet and at least 4 clamps...I always get extra clamps and hose length to have as extra.

Kendrick

· #14 · Jun 9, 2011

planner3357 said:
The 7.5mm are usually only special items. Your best bet is to get them online somewhere like International Auto Parts.

Metric Fuel Hose by the Foot

You need 7.5mm high pressure fuel injector hoses with the necessary clamps.

I had to call them and make sure they put the clamps in there too.

Your problem was both the hoses and clamps were too big. Get a couple feet and at least 4 clamps...I always get extra clamps and hose length to have as extra.

Thankyou! So i'd be unable to purchase the hoses at a typical autoparts store around my area? I should buy the ones on the link above? 7.5mm and maybe 2 or 3 feet you would recommend?

Is the 4 clamps included with that order? or would i have to buy them, and do regular fuel hose clamps work? Or i need special ones too. Thanks!!

-Kendrick

planner3357

Discussion Starter · #15 · Jun 9, 2011

You won't find them at a regular auto parts store. I tried all of the major chains, even a local foreign parts place and no luck. I couldn't find the clamps on the website so I called International Auto and placed the order for hose and clamps. You need these clamps to go with the hose. Regular will not work.

Kendrick

· #16 · Jun 9, 2011

planner3357 said:
You won't find them at a regular auto parts store. I tried all of the major chains, even a local foreign parts place and no luck. I couldn't find the clamps on the website so I called International Auto and placed the order for hose and clamps. You need these clamps to go with the hose. Regular will not work.

It turns out the hose is out of stock!! -___- What luck! HAHA, well. Thanks tho, ima put an order for 2? or 3? (what do you think) of fuel hose tonight, and they'll ship it once they get more. And i have to call them to add clamps? do i have to pay for that as well?

UGH, yes i do to love these cars. Thanks for the help brother!

planner3357

Discussion Starter · #17 · Jun 9, 2011

When I ordered the hose no clamps came with the order, so I had to call and order them separate, yes they cost $. I would order the clamps at the same time as the hose as to not have two separate shipping fees like I got screwed over on.

I ordered three feet, never know when you'll need more hose.

goats

· #18 · Jun 9, 2011

go to your local BMW dealer

and get the proper hose and hose clamps. They stock 7.5 mm FI rated hose

planner3357

Discussion Starter · #19 · Jun 9, 2011

goats said:
and get the proper hose and hose clamps. They stock 7.5 mm FI rated hose

One would think Goats....but I went to my local BMW dealership parts dept. and they looked at me like I was crazy. They said they don't stock that stuff..unbelievable. I even went to the Exotic Dealership (Ferrari, Maser, etc...) no dice.

This is why I used International Auto.

Alfisto Steve

· #20 · Jun 9, 2011

planner3357 said:
One would think Goats....but I went to my local BMW dealership parts dept. and they looked at me like I was crazy. They said they don't stock that stuff..unbelievable. I even went to the Exotic Dealership (Ferrari, Maser, etc...) no dice.

This is why I used International Auto.

Bimmer parts dept people can't think outside of their small box mentaility. They only seem to be able to deal in whatever BMW series and year that comes up on their computer screen.

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