Exhausts and economy questions.

[Crash Lander]

Howdy all.
I posted last week about my S1 AU stalling on start up. You guys suggested cleaning out the TB and something else on the top (can't remember what it's called).
Anyway, it was time for some much needed TLC on the old girl.
I used to change my oil every 5k, but for various reasons was not able to of late, and so the oil that I changed yesterday was almost 20k old. In that time however, it only used maybe 500ml, so I'm happy. Changed to Magnatec, and a new filter too of course. In another 5k, I'm changing them both again, come hell or high water.
I also changed the plugs, which have been in the car for about 45k. I was surprised to see that the plugs were still in excellent condition. Nice colour, no build-up etc. Put new ones in, so that jobs done. The leads are about 45k old too, so they can stay for now. I'll replace them again in the new year.
Next job was the tensioner and pulleys.
This job was not at all difficult until it came time to fitting the new belt. This took ages. Then I bit the bullet and removed the thermo fans and that gave me enough extra room to get the belt done in minutes! Should have done that right from the start.
The thermo fans are a bugger to get out with the metal pipe in the way on the drivers side of the radiator, and the top radiator hose neck blocking the other side. With some swearing, a nice chunk of flesh out of a knuckle, and some creative wiggling, I got it out. Putting it back was a reverse of the removal, minus the knuckle skinning. Did manage to break a piece of the shroud off, but only a small piece! DOH!
Fired it all up, and it started first go. No stall either! This mornig was the real test, as it hadn't been run over night, and again it started first pop with no stall, so the problem has been fixed.
I promise to the Ford God, that I will get back into my regular servicing from now on!
I should say that even in it's state of neglect, it does give me excellent mileage, and has never caused me any drama apart from the stalling when first staring in the morning.
Now, here's the next question.
When I started it for the first time, I let it idle and checked underneath for leaks. I found something dripping from the exhaust. Turned out to be water coming from a flange just rear of the cat. Condensation obviously. I put my hand under the flange, and it's leaking exhast. Will this effect my fuel economy? I do need a new exhaust system, but it has to wait until the new year. I also noticed that all the rubber rings that hold the exhaust to the underneat of the car are perished, and several are broken. I'd guess that's why the system is leaking because it's supporting some of it's own weight. Once I get this leak sealed, should I see even better fuel economy? More power maybe?
I'm planning on a 2.5" cat back system next year, because I've heard they're not much dearer than a standard system, so it would be silly not to do it.
Comments?

[JC]

Originally Posted by Crash Lander

When I started it for the first time, I let it idle and checked underneath for leaks. I found something dripping from the exhaust. Turned out to be water coming from a flange just rear of the cat. Condensation obviously. I put my hand under the flange, and it's leaking exhast. Will this effect my fuel economy? I do need a new exhaust system, but it has to wait until the new year. I also noticed that all the rubber rings that hold the exhaust to the underneat of the car are perished, and several are broken. I'd guess that's why the system is leaking because it's supporting some of it's own weight. Once I get this leak sealed, should I see even better fuel economy? More power maybe?
I'm planning on a 2.5" cat back system next year, because I've heard they're not much dearer than a standard system, so it would be silly not to do it.
Comments?

Good job on getting the thingy idling nicely.

As for the exhaust - a leaky exhaust won't rob you of much power or economy if it's after the cat, as the O2 sensor is before the cat, and it helps control fuel maps etc. A leaky exhaust is, however, dangerous, in that the fumes can make their way into the car - which can be deadly!

A 2.5" mandrel bent redback cats back system will set you back about $380 odd from ebay, but you may be able to source one cheaper from an exhaust place. Sounds like you will also need some hangers - should be no more than $5 each. Fitting is pretty easy - unbolt the rear "over diff" section and separate from the front pipe section (hammer works well), then unbolt from the cats flange, and separate the whole front pipe from the car. Installing the new system is a reversal of the removal procedure - you may have to swap at least one bracket between old and new, and you will need to resuse any of the good rubber hangers, and use the new ones where the old ones are broken.

Or - you can just get the whole thing supply and fit for between $300 and $500 depending on where you live - Sydney and Melbourne seem to be more price competitive than, for example, Canberra - the ebay & self fitting option saved me over $200!

Last time I priced one stock centre muffler, it was around $300 fitted.