Expensive Noises

[S2central.net]

Well there I was... at full chat going from 4th to 5th past a long line of traffic on a wide open A road and there is this mighty bang followed by what sounds like a misfire and/or blowing exhaust.

Scared me witless - its all going thru my mind - all this time on chips (and the new set I'm brewing now) with an engine at 119k miles - I'm thinking that something major has bit the dust and I can almost see the extra zero being added to my Visa bill. Oh sh*t

Car is still pulling OK, no smoke, pressures & temps OK and I'm less than a mile from home. I carefully bring her back home and am sure that I can smell exhaust gas, thinkin' I must have cracked something...

Then I remembered that just yesterday I had fitted the CO measuring tube onto my exhaust downpipe (these were only fitted on 3B in the factory) so I wondered had it worked loose... Oh no - the attached photograph tells the story much better. Too much of a coincidence.

Guess the factory bung (brand new) ain't rated for the kind of exhaust gas pressures when humping 1.45 bar around. The bung didn't last 50 miles so I gotta wonder has anybody else had this happen to them. Maybe I got a dufff bung.

Must admit it didn't feel somehow right when I squeezed it on so there's 20:20 hindsight for you. I'm thinking that a neatly made metallic insert for the bung might be an improvement.



Cheers & Phew

Paul

[Josh-stateside]

I am thinking of using that hole for the EGT gauge that I have.

Well that is if I can get that bolt out with the impact wrench.

[Mihnea]

Josh, you'll be able to get the bolt out but my advice is to heat it well first, then use the impact wrench on it. Once more, heat it well!

Paul, you scared the sh*t out of me dude!

[MikQuattro]

Paul, you scared the sh*t out of me dude!

Me too!!!! :eek2:

[Mihnea]

Oh yes, Paul, before I forget:

You seriously need to get rid of your cats m8, that "bung" (didn't know bung could be used for such a thing?) isn't supposed to blow, even when not attached with a clamp, so this means the pressure you're getting in the exhaust after the turbo is way too high and has no way of going totally through the cats, hence the bung blowing.


Cheers,

Mihnea


PS: any news on my 3B generic load?

[S2central.net]

Yeah its weird - the misfire and orrible noise was most apparent in the 2-4k range.

It did make a helluva strange noise when it blew off - just as I was passing a convertible BuM-Wiper - he must of had a shock !

@Mihnea - I have the new 3B load ready to go for Dave's car and we'll get them tested very soon I hope. Will let you know ASAP.


Cheers,

Paul

[SteveH]

Paul,

I had exactly the same problem with the replacement bung I bought recently. It didn't blow off, but split into two or three bits within a couple of days. The new rubber bungs are brownish in colour and seem to be made out of really hard rubber, whereas the original one on my S2 was blue and made out of softer stuff.

I think my problem may have been caused by the jubilee clip biting into the rubber and splitting it. I've put my new replacement bung on without a clamp and it's still there 2 months later.

HTH
Steve.

[s2driveruk]

SH*T - I have a knackered, orange - heat baked one on my car - looks like the original - thought about replacing it but might wait now untill you find a decent solution.

Cats are coming off mine soon anyways - keep grounding the car out on those flat topped sleeping policemen

Get the MOT done in oct with them on then time for a new fabricated connection from the downpipe to the two aft pipes from the rear of the cats. I am assuming its best to keep those twin pipes from behind the cats to retain a bit of back pressure that splitting the exhaust gasses will cause? Having said that they are 2 x 2.5 inch so probably be no back pressure anyways right???

Am I going to wake the neighbours when these cats go - already set their car alarm off when i start mine first thing in the morning lol!

Cheers,

David

[Greg_S]

Originally posted by Josh-stateside
I am thinking of using that hole for the EGT gauge that I have.

Well that is if I can get that bolt out with the impact wrench.

Thats exactly what mark H has done on his think he got the kit from Greddy with sensor etc.

[audiman]

Mines the original one made in 1991. Never blown one apart!! Run for 10 years with the cats! Must be a dodgy one.

Never doubted the chips Paul. They are good stuff!!