2000 156 TS - centre muffler broken

[MattK]

Nice one, thanks! I'll ask them for a quote and look at buying the part if they're way over that. I feel I should take it to a shop rather than DIY because I'm pretty sure there's a manifold leak too, I can hear that flickering/fluttering sound which is almost like a valve noise.

[MattK]

Alternatively, you can have aftermarket cat + muffler for around $250 delivered.

You saved me a BUNDLE. I went to Moonah Mufflers (so far, a recommend for any Hobart folks reading) and they had a look on the hoist, confirmed that the rattle is loose broken stuff inside the cat assembly, and warned me that the Alfa part would be expensive because of the weird setup inside (the guy reckoned two cats and a baffle box). I said hey I can order this one from the UK for $260 and his eyes widened, he took a look and said yeah that's it all right, go for it! Reckoned he couldn't even get an aftermarket replacement for that price and that it'd be a bad choice anyway because it'd make the car sound bad. Said it'll be $50-70 to fit and won't need any new gaskets or anything. And then gave me a tip on where to find cheap parts for European cars in town.
Only drawback is I have to wait six weeks for delivery. Oh and the fluttering noise isn't a manifold leak, worse luck.
Anyway HUGE thanks to the members here who took the time to help and shared their expertise.

[Citroënbender]

Can they have it overnight for "further testing"? 

[MattK]

Ha - I don't think a well-mannered 2 litre saloon was making anyone's pulse race there (except mine). For what it's worth the guy agreed that the loose parts inside would be causing my power losses (funny how blocking the exhaust flow affects the engine's running). I was kind of hoping he'd drive a screw through the side to pin it down for a couple of weeks, but I guess that would produce catalytic confetti.

[bonno]

Matt
Contact the seller thru e-bay and request for quote for delivery to Hobart URGENT delivery (2-3 days)  or just wait the 6 weeks. Did the muffler guy mention anything regarding any short term damage if left and driven this way. Maybe check with him to verify prior to getting it delivered ASAP and paying the additional cost for freight.
cheers
bonno

[Citroënbender]

The joys of Tas Post. Order, wait, wait, wait, declare item MIA, re-order, wait, arrive massively damaged, re-order, wait, receive damaged but usable.

[MattK]

They didn't seem concerned about it, I just drove it in, they put it on the hoist to check out, then I drove it away. If I had to guess I would say the power loss is more an engine management thing based on anomalous sensor readings, rather than something mechanically risky. It's been driving pretty well the last few weeks with occasional slowdowns - it's more the rattle noise driving me insane.
If people feel it's a risk I am prepared to listen to reason though.

[Citroënbender]

Don't load the motor excessively, watch your temp gauge and monitor the oil level.

Is your thermostat good? Many at that age are overdue for replacement if never done before.

[MattK]

I'm getting a timing belt change in the near future, I expect Steve will look over the pulleys and he mentioned the water pump - I'll ask his opinion on the thermostat. It had a pretty solid service history when I got it, but no indication of a belt change.

[poohbah]

Its generally worth changing the water pump at same time as the belt, and absolutely if yours still has the original plastic impeller.

[bazzbazz]

ALL Pulleys, belts AND Water Pump MUST be changed when doing a cam-belt change. To do otherwise invites disaster.

[bonno]

Agree, too risky to do otherwise. Just gone thru purchasing through e-bay cambelt and balance shaft kit that includes idlers and water pump for my 2.0L JTS at a cost of under $350.

[MattK]

Will definitely get the whole thing changed out - I doubt Steve would let me get away with a half done job.
Had some odd noises sounding like belts rubbing on plastic covers today. Took it home but the noises stopped on the way, replaced by a bit of a moan from what I think might be the power steering pump (it changed pitch as I turned the steering wheel). Accessory belt for that?

[johnl]

Sounds likely to be a PS pump, which tend to make a moaning noise that rises and falls as the steering is turned. Have you checked the fluid level? Low fluid often causes PS moan.

My old Accord once developed a problem with the auxilliary belt rubbing on the plastic timing cover (sounded a bit like a not very load supercharger belt drive). It never caused a real problem and after a while it went away, but while it was happening I failed to find where the noise was coming from, despite looking and looking (yes I'd have thought it would have been easy to find too...).

Found the problem eventually when I took the auxilliary drive belt off, and found the old evidence on the cover behind the belt edge. It went away of its' own accord (no pun intended) because the belt rubbed the plastic away until there was no longer any contact, just a slotted hole in the cover...

Regards,
John.

[MattK]

The fluid is touching the MIN mark on the little dipstick - I guess I could top it up to see if it helps. Will any red PSP fluid be OK, or is there a specific recommendation?
Also the fuel tank sender reports half a tank when it's full - should I be hunting a bad connection or is a problem with the sensor more common?