Exhaust downpipe fitting. (Catalyst front pipe variety)

[Bremar 6]

Hi,

This was going to be a simple question about the large wire wool crush ring at the junction between the manifold and downpipe and 1. whether people always put on a new one or left the old one in place and used that and 2. Anyone use exhaust paste on it. The one already on the car is reluctant to let go of the manifold. 
however, please see attached picture. The old exhaust has a spliter in it that matches the manifold split. (Looks the same if you look into the manifold) but the new exhaust is just open?? Anyone have any experience of this and the effects of not having this splitter in the top part of the exhaust. 
thank you. 
Bremar

Edited February 6 by Bremar
Left stuff out.

[Leslie green 116]

I put a new wire mesh sleeve /exhaust ring on  , they can take a fair bit of battering to remove with a chisel or screwdriver as it will be rusted solid now and no exhaust paste needed .

 The split is what peugeot fitted and extends about 2 foot down the pipe if its like the pre cat cars .You dont get it with aftermarket parts as its probably expensive to make with about 4 foot of weld. The split is usually burned through so if its mint like that id try and save it , its to give a 4 into 2 into one exhaust without using 2 separate pipes from what I understand it. It wont be doing much on the gentry I suspect with its lower tune but nice to have.

I fitted a genuine used split downpipe to my new system as it was bent at the wrong angle and wouldnt meet the manifold correctly. 

Edited February 6 by Leslie green

[Bremar 6]

Thats very helpful Leslie. I’m fitting the new cat front pipe because there’s a rattle from the old catalytic converter box and I can then het a stainless middle and rear box fitted. 
the divider on this cat frong pipe only extends 9 inches. See pick. 
The kit I bought from ebay has all the correct sized parts for the 205 plus 2 other fancy silver washers. Again please see picture. The original fitting doesn't appear to have them. Do you are anyone else have any ideas why they are there. 
Thanks Bremar. 

Edited February 6 by Bremar

[Gohn 69]

all of those fixings/washers are standard

the only difference is the springs of the new ones aren't made out of the same type of metal

the pipe separator also exists on the XU5 (1.6l) and is to try and keep the exhaust gas flow more laminar (that's what I thought anyway)

 

I put a lot of tin/copper antisieze grease all over those exhaust fittings, especially the top cups

they're always getting very hot which promotes corrosion

[Leslie green 116]

The dimpled washer goes in the cup against the spring .

[Bremar 6]

Thank you Gohn and Leslie, that nicely covers my  issues. The kit did come with a pair of different sized springs and bolts so I guess covers another Peugeot model? If all 205’s have the same fittings.  Hopefully get the new one on this weekend.

thanks again Bremar. 

[Leslie green 116]

The other springs are too long for the bolts , on mine the flange was about 15mm and none would fit although I have seen longer bolts for sale.

[petert 601]

You’ve lost part of the 4-2-1 design. It will be interesting to know if you can tell any difference.

[SRDT 189]

The old XU5S from the 305 and BX had a proper 4-2 cast iron exhaust manifold with a 2-1 twin tube front pipe and then the flexible junction.

Peugeot quickly managed to make tubes with the internal spliter so that's what the 205 GTI had from the start.

[Bremar 6]

I have now fitted the front downpipe. I think as was mentioned the springs I chose as a close match were slightly longer than the original ones but tge correct diameter ( I just thought that that was because the old ones had been compressed),  however when I was trying to fit them I could not get the nut onto the end of the bolt. In the end I had to go back to using the original springs as that was the only way to get everything else back together. This  YouTube vid of kit I bought off EBay might help others. 
thanks Bremar 

 

[Leslie green 116]

My kit came with 2 sets of springs ,was bought ages ago though, one set looked identical the the ones fitted before.

Edited February 11 by Leslie green

[petert 601]

All the kits I have purchased have come with three pairs of different length bolts. Also, those nuts look like nylocs? If so, they'll last 5 mins. You need to use a crimp style nut. eg. conelock

 

Sometimes it helps if you use plain nuts first to assemble it, then replace one at a time with crimp nuts.

Edited February 13 by petert

[Bremar 6]

Hi Petert. 
the nuts are crimp style they are not nyloc nuts. The bolt’s and nuts weren’t a problem it was that the springs were wrong so I had to use the old ones, which in my case were fine. Always a real pain when you buy something that is supposed to fit but doesn’t and by the time you find that out you've already dismantled the stuff. Suffice to say I can not recommend that particular kit.  
Thanks Bremar.