1st Gen R53 Cooper S 02 Mini Cooper S blew exhaust flange welds

Discussion in '1st Generation: 2002–06 R50, R53 & 2004–08 R52' started by Tummi_Gummi, Sep 11, 2013.

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  1. Tummi_Gummi

    Tummi_Gummi New Member

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    #1 Tummi_Gummi, Sep 11, 2013
    Last edited: Sep 11, 2013
    my car starting hissing super loud. From inside it almost sounded like an air leak in my firewall or something.
    When i got back home i put a jack under the car and found the flange that bolts the cat to the resonator broke off and was leaking exhaust pretty bad. It was a pretty good size leak.
    [​IMG]

    Here are the goods.
    Car is idling fine.(Not rough/missing or at abnormal rpm and sounds good)
    No smoke from anywhere
    No strange smells
    No check engine lights
    Car seems to be boosting but slightly slower.
    Still a loud supercharger whine

    The bad.
    Distinctive exhaust leak sounds from under the car
    very loud hissing noise under acceleration from the air filter
    Car has lost power. Not all, but some. Seems like just a couple psi

    Here is a video of the sounds
    [ame=http://www.youtube.com/watch?v=-O9zdJsM1Ls]Mini Cooper blew exhaust and maybe supercharger - YouTube[/ame]

    I am wondering if this hissing noise is from the exhaust leak.
    It kind of sounds like a scuba diver breathing from his air tank

    :mad2::mad2::mad2::mad2::mad2::mad2::mad2::nonod:
     
  2. mrntd

    mrntd Well-Known Member
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    #2 mrntd, Sep 11, 2013
    From the pic it looks like the lower bolt is broken. That would cause a leak from the between the flanges.

    I had this exact thing happen last year on my WRX. It looked ok until I went to check the tightness of the bolts and the the one sheared in two. It broke in between so both ends were still there.
     
  3. Thumper460

    Thumper460 Active Member

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    #3 Thumper460, Sep 11, 2013
    I would agree.. it is all exhaust related!! I gave up on mine..lol. Running hard and long, or making short bursts on Nitrous Oxide.. those gaskets don't hang too long. ( neither do O2 sensors..) I do have a pretty loud exhaust so the add'l noise is just that... noise!! When I want quiet.. I replace and rock!!

    As for the exhaust leaks causing any drivability issues.. mostly NO, it is just a freer flowing exhaust..

    Just me...................

    Thumper
     
  4. countryboyshane

    countryboyshane New Member

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    #4 countryboyshane, Sep 11, 2013
    Sheer 4-banger power! Time to upgrade to some grade 10.9 bolts down there!
     

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