This weekend I finished replacing my exhaust system that I purchased during my buying spree (http://www.peachparts.com/shopforum/showthread.php?threadid=29542)

When I was taking the exhaust system out it came out in 2 pieces: The top half of the down pipe and the bottom half of the down pipe + the rest of the exhaust. Yes my Down pipe was broken in 2 pieces since I got the car. That break also contributed to: black goop all along the bottom of the engine compartment, smoke coming from under the car, and a louder then what I presume normal engine sound (I never really paid attention to the exhaust note of other 300D's).

The installation was very easy since the new system came in 3 pieces: the down pipe, middle, and muffler. The old system was 2 pieces: Down Pipe, the rest. I first put the down pipe in place with all the bolts tightened loosely. Then I hung the muffler from it's 4 hangers. I was then able to fit the intermediate pipe in between. The only hard part was holding the Intermediate pipe up while tightening the bolts.

When I went to start up the car I was shocked at how quite it was, it was if my engine wasn't running at all. I would have taken it out for a test drive but the left rear brake caliper has sprung a big enough leak to render the brake system useless. (I would have loved to take it for a drive since the weather currently falls into the "Perfect" category)


Some things to remember if y'all are going to replace your exhaust system: get new bolts to connect the Intermediate pipe to the down pipe, get an 2.5" x .25" U-Bolt and nuts from Mercedes to connect the Down Pipe to the bracket that keeps it from rattling, no automotive stores care that narrow a U-Bolt in stock. I also tried the local Hardware stores but they seem to be poorly stocked since they didn't have them either. Either way, get that U-bolt from Mercedes and save your self the hassle.

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2005 Audi A4 1.8T CVT -Silver/Black "Siegfried"

1982 300D - Silver/Blue "Ralph" -For Sale:
http://www.peachparts.com/shopforum/showthread.php?p=852260

1989 VW Diesel Jetta Blue/Blue "Bodo" RIP

Did you have to deal with any rust? I'm considering replacing my exhaust system eventhough it's intact with no cracks or rust-through spots. I'm hoping new equipment will help make my car a little quieter. Also, how long did this take you? Thanks a lot

Alex

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1983 300D (parked for four years)
2012 VW Sportwagen TDI Manual
2001 Miata SE
1962 Chevrolet Corvair Rampside

Since I'm in Texas there was hardly any rust on the actual Exhaust. There were some holes in the muffler but that is about it. As far as loosening the bolts - it was pretty easy, they weren't siezed up (although I did spray them down with WD40).

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2005 Audi A4 1.8T CVT -Silver/Black "Siegfried"

1982 300D - Silver/Blue "Ralph" -For Sale:
http://www.peachparts.com/shopforum/showthread.php?p=852260

1989 VW Diesel Jetta Blue/Blue "Bodo" RIP