Exhaust problems with 2010 1.6 TDi

[Diesel Do]

Hello all. Newbie here, posting in hope there's a way of avoiding spending £1k+ on getting my exhaust fixed.

My 2010 1.6 TDi (75bhp) failed its MOT due to emissions that the garage suspects is caused by the hole in the flexi pipe just in front of the DPF. Some genius at VW decided to make the front bit of the exhaust an entire piece, so to replace the flexi pipe, you actually have to buy the entire front end, which includes the Cat, DPF and flexi pipe, for the princely sum of around a grand. Nice one, VW. No, really.

Is there a way around this? And if so, has anyone ever done something along these lines? I was thinking it must be possible to get a new section of flex pipe, cut out the old section and just weld the new section in, but I have no idea. It just seems like such a huge expense for what's likely to be just a hole in one small bit of the exhaust.

Any help/pointers gratefully received. Alternatively, if anyone's breaking a 2010 1.6 TDi and fancies selling me the exhaust system for a reasonable sum, I'm all ears.

Thanks!

[iichel]

Perhaps you can contact an exhaust expert? Keep in mind, getting this section of the exhaust out is not very easy and labour costs will be high anyway.
The part itself is also very expensive (the quoted 1000 GBP sounds cheap to me).

[Diesel Do]

Yeah, I think I'm going to have to see how much it would be to repair. Assuming it's possible to do that.

Otherwise it's not worth fixing. Could pick up a 'new' second hand one for the price of replacing the exhaust/labour costs. Not quite sure why VW saw it necessary to design it so the whole front end needs replacing if you get a hole in the flexi pipe (which is quite likely). DPF and Cat are fine, but obviously the expensive bits to replace.

[RUM4MO]

Any proper exhaust builder will have access to "flexi repair sections" and be able to remove the old one and weld in a new one, most other places would rather empty your wallet for the complete part though, just because they are lazy and maybe even not too good at welding!

I got that part sorted out on my wife's 2002 Polo 1.4 16V BBY engine when it was only 5 years old, as at that time only genuine VW Group parts were the alternative - and for only the pipe and cat it was over £400 back in 2007, so I needed to find a better solution - which worked for the remainder of that car's life with us, ie 105K miles and 13 years from new.

[Diesel Do]

Great stuff. Yeah, I thought that must be the case. It's such a small element of the whole front end. You'd think VW would design it so it was individually replaceable rather than having to cough up for a new Cat and DPF as well if it gets a hole in it.

I'll get on to the exhaust repair lot and see what they say. Cheers.

[RUM4MO]

Somebody put me onto a company called Senior Aftermarket and I chose the correct type, highest protection as it was after the CAT and correct diameter, flexi length and stub ends.

What really did happen is, I found a local exhaust design/fabricator company who specialise in building replacement or bespoke exhausts for mainly older or specials, not a problem for them it seemed.

I collected the car a few hours later and noticed some unwanted resonances appearing, and the next day discovered that when reversing up a steep driveway, the exhaust was touching the body somewhere, not a happy bunny!

So, I posted these facts on the Skoda Fabia motoring forum and requested that someone measure their original flexi section, checked on Senior Aftermarket for an exact repair flexi section, found one and ordered it.

By this time I had worked out that my "specialist" had just fitted all he could get his hands on from his exhaust parts delivery man - the flexi section was too short and its diameter was at least a size bigger than my exhaust before and after section, plus the stubs/tails were too big a diameter!

So I phoned up and told them of my findings and they assured me that as they knew all about designing bespoke exhausts, I was completely wrong and that for a short section none of what I had found could cause any issues, but they did agree to remove what they fitted and fit what I was supplying for a (high) nominal cost. The result was like chalk and cheese, the car was then back to being like it was prior to that flexi section tearing open. Actually in my case, it looked like the fabrication of the original factory fit exhaust was at fault ie the join as too neat as in not enough welding!

So, beware it seems that calling yourself an expert does not always mean that you know your stuff - at the end of that repair they almost admitted that they just used whatever was available to them - and the rest must have been flannel bluster and bluffing.

[Diesel Do]

Blimey. Sounds like a right pain.

I've been quoted around £280 + VAT for the repair work, which is considerably cheaper than the £1,000+ for just the part. Might not have to sell the old girl after all.

[RUM4MO]

Remember, I might have been very unlucky and maybe things have improved in general for sorting out fractured flexi sections of exhaust pipes, my repair job was from over 12 years ago.

Also location location location.

Good luck!

Edit:- my original (duff) repair was £120 all in, then I had to pay another £60 to swop flexi repair sections, so your price looks very fair for the 12 year space in time.