I suspect my daughter's car has a cracked manifold - there is a very loud (and getting louder every day) exhaust leak somewhere towards the front of the exhaust system. Looking at parts online it looks like the integrated manifold and cat is the same for the Base Cooper as for the S. Is that right?

See image below from partsgeek.

Ian

 

get it welded!

 

I just have to find a muffler shop that's willing to do that.

Ian

 

I took the first one to a welding shop and they charged me $70, but I did remove it first.

 

I don't have a lift. Not sure I'll be able to get it out just raising the car with a floor jack and axle stands. I don't know if I'll have the clearance.

Ian

 

I just posted a new thread yesterday on my experience with getting the Cat welded.
There are absolutely no issues with clearance while it's on jack stands. It's a very straightforward job.

 

X2, I did it on jack stands with no issues and it was quite easy.

 

Thanks, my concern is damaging the cylinder head while removing the manifold bolts. Are they hard to break free?

 

No, they are usually easy. Remove the upper engine heat shield, to give you visual access. (two bolts)

 

If they seem to resist, buy a can of CRC Freeze off. It is the best penetrating\ catalyzing nut and bolt remover.
I have used this since it came out and it works great!

 

My exhaust manifold/Cat broke in half. I purchased a used one from a NAM member for $150. I spayed up the bolts with penetrating oil, but I still had a few bolts with rounded head, spent a few bucks and got a set of 3/8 inch Bolt Extractors. I also replaced the rounded bolts with new ones. It;s a simple job, even doing it on jack stands. While you have the exhaust manifold off, it you have any leaks from the Oil Filter housing or Oil cooler, it's very quick work to replace the gaskets/seals with the exhaust manifold removed. may the Force be with you....

 

Well, the happy news is that the muffler shop was able to weld the cracked cat in-situ for the princely sum of $45. The less happy news is that the shop thinks there may be an internal engine issue based on some rattling noises coming from the motor. This is quickly exceeding my pay grade, so my daughter is going to take it to a local shop we trust to have them do some diagnosis.

Ian