Technical Replacing whole exhaust on a mk3 panda

[Smallcarflinger]

I got a cheap mk3 panda for my first car, its been great fun to use and drive but I am very aware of the exhaust, which on its MOT advisory has the front and rear listed as leaking a bit.
I've looked through the engine bay and can see that the front is definitely very rusted.

I've taken the car to a garage and they have said there are no issues other than that, but they said that they can only replace the rear exhaust, and that the front WILL NOT be replaced by anyone. Basically that the way the exhaust is the engine rests upon it or something and is dangerous to do? (roughly what he said from memory)
This is the first i've heard of such a thing and have been unable to verify this is the case.
Obviously i'm not a mechanic so I don't know but the engine seems small enough that I don't see why it couldn't be done

Is this definitely the case/have any of you had to do/get a front exhaust replacement? if so is it worth doing or just using the car till it dies. I got it for very cheap so it probably wouldn't be the end of the world if it only lasted a year but i've grown fond enough to be willing to take it to have that done, especially before i do anything else.

 

[jrkitching]

There are three parts to the exhaust system; a combined manifold/catalytic converter at the front, a centre pipe with a short integral flexible section at the front, and a rear box silencer with an integral short pipe section at the front.

The front manifold normally lasts the life of the car; it's replaceable but expensive. The other two sections are just mild steel exhaust parts and are commonly replaced together. Separating them is likely to be difficult/impossible, and if one has rusted out, chances are the other will have also.

There is a fixed rigid two part bracket at the front, which firmly secures the cat to the transmission housing; this is known to rust away and should be replaced if there is any doubt about its condition. If this bracket is compromised, the whole exhaust can flex and put enough pressure on the manicat to crack it and break its mounting studs; if that happens, you're facing an expensive, awkward and non-straightforward repair.

Generally speaking exhaust replacement involves replacing the centre and rear parts.

 

[The Panda Nut]

There are three parts to the exhaust system; a combined manifold/catalytic converter at the front, a centre pipe with a short integral flexible section at the front, and a rear box silencer with an integral short pipe section at the front.

The front manifold normally lasts the life of the car; it's replaceable but expensive. The other two sections are just mild steel exhaust parts and are commonly replaced together. Separating them is likely to be difficult/impossible, and if one has rusted out, chances are the other will have also.

There is a fixed rigid two part bracket at the front, which firmly secures the cat to the transmission housing; this is known to rust away and should be replaced if there is any doubt about its condition. If this bracket is compromised, the whole exhaust can flex and put enough pressure on the manicat to crack it and break its mounting studs; if that happens, you're facing an expensive, awkward and non-straightforward repair.

Generally speaking exhaust replacement involves replacing the centre and rear parts.

1.2 bore size is different to 1.1. Get the right size. Any garage can easily do the echaust. Its a simple job.

 

[koalar]

I think something got lost in the translation from the mechanic and here

the front WILL NOT be replaced by anyone. Basically that the way the exhaust is the engine rests upon it or something and is dangerous to do? (roughly what he said from memory)

Any part of the exhaust system is replaceable

And is easy for a garage to replace

Front, middle (centre) or rear

It's rare for the front to fail, unless it cracks due to impact damage

Advisory on an exhaust rear (back box) is common

leaking at the front is commonly the flex joint which is part of the centre section


What happens if you put your hand over the rear of the exhaust while it's running, does pressure build up can you hear where it's leaking

 

[jrkitching]

1.2 bore size is different to 1.1

And the 60HP 1.2 has a different bore size to the 69HP 1.2, although the parts look similar.

 

[AnthonyH]

I got a cheap mk3 panda for my first car, its been great fun to use and drive but I am very aware of the exhaust

It looks to me you're inviting trouble into your life. Cars can be a lot of trouble.

You could easily get stung for £500, or the garage could hand the car back with a different problem through their incompetence.

Do yourself a favour and stop thinking about it. Problem solved.

 

[DaveMcT]

That bracket at (7) is extremely important**. However it is mild steel wrapped around a stainless pipe the end just rusts to nothing. A new OEM bracket can only be fitted when the exhaust is replaced. I made a replacement with an exhaust clamp and stout bracket. When the clamp rusts out its easy to replace.

** When the bracket fails, vibration will eventually crack the catalyst outlet area. It can be welded but the manifold has to be removed from the car. Expensive.

 

[jrkitching]

A new OEM bracket can only be fitted when the exhaust is replaced.

They can be fitted with the exhaust in-situ by opening them out sufficiently to pass over the pipe. I've done this myself with a known OEM bracket bought from a main dealer.

Obviously easier with the exhaust off; remember to slide it over the pipe before putting it all together!

This bracket should always be replaced when changing an exhaust; then inspected annually and changed if significantly corroded.

 

[Yolanda]

I recently changed the middle section. I bought one off ebay but paid a little extra for one with a 5 year guarantee, for £49.88 from a company called RTG Automotive. It came in two pieces with clamp. At first I thought the diameter was larger than the one I took off but it wasn't it was down to the thickness of the metal. It fitted perfectly, the only issue I had was separating the back box from the old pipe that's where the vice and and plenty of heat came in.
I fully appreciate that not every one can fit them themselves, but you can buy one and give it to your garage to fit. If the car's a keeper as they say, you're better off buying a good quality one for not much more money if you shop around.

 

[DaveMcT]

Our first Panda ran around for quite some time before I realised it even had a bracket at the catalyst outlet pipe. The ends had rotted off so neatly it wasn't obviously an issue. That's when I made up the bracket with a U-bolt exhaust clamp.