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Author Subject: replacing the cat...
barrym

Senior User

Location: Westcliff-on-sea

Registered: 26 Jun 2014

Posts: 502

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Post #1
The cat part of my exhaust has failed big time, practically hanging off.

The cat is the original but was only refitted 5 months ago to replace a decat. Not by me obviously as I wouldn't be asking !
Got a new one ordered, no problems there. My question is are there any un-obvious pitfalls when removing/refitting one? ie. what sealant to use, gaskets etc? The fitting kit on servicebox looks quite complex too, also any special-ish tools needed to release the manifold end of the pipe?

Got one day off work to do this so need to be prepared for anything

Help me please guysBig grin

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China D Turbo HDi daily charger
Black Rallye occassional toy
Posted 17th Nov 2014 at 17:14
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dangti6

aka JKshooter

Location: Taunton, Somerset

Registered: 15 Jun 2006

Posts: 10,305

Status: Offline
Post #2
Have you bought a pattern part?

They don't last apparently.

10mm ring spanner for the top of the fitting bolt, deep 10mm socket on the bottom. I do it all from underneath with arms around the subframe.

My advice would be to wear goggles. You may find you knock the protective bag on he steering rack ram (if it's there!) and get a face full of old water mixed with PAS fluid and a decades worth of grit and grime in your face.

It's not a tricky job tbh.

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  • Senior Test Automation Engineer for the 306GTi6 Owners Club Forum Wizard

    • Posted 17th Nov 2014 at 17:30
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    barrym

    Senior User

    Location: Westcliff-on-sea

    Registered: 26 Jun 2014

    Posts: 502

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    Post #3
    Thanks Dan.

    Yes I bought a pattern part. Hmm not good they don't last but coming up to Christmas needs must and all that. It was only £63 quid anyway.

    From experience when fitting a replacement HP steering pipe I know for sure the protective bag is gone.

    I have all the tools you mention so hopefully it will go well and I can spend the rest of the day fitting my BBM engine mountsThumbs up

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    China D Turbo HDi daily charger
    Black Rallye occassional toy
    Posted 17th Nov 2014 at 17:42
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    demondriverdan

    Seasoned Pro

    Location: Londinium

    Registered: 29 Nov 2010

    Posts: 2,665

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    Post #4
    It's not particularly tricky but a fiddly job, mainly undoing the manifold to cat bolts. I think the fitting kit comes with several different length springs in which case you need the longest one.

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    Rallye Race Car
    Posted 17th Nov 2014 at 18:14
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    barrym

    Senior User

    Location: Westcliff-on-sea

    Registered: 26 Jun 2014

    Posts: 502

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    Post #5
    TBH I wasn't planning on getting the fitting kit. Do I really need to?

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    China D Turbo HDi daily charger
    Black Rallye occassional toy
    Posted 17th Nov 2014 at 18:18
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    dangti6

    aka JKshooter

    Location: Taunton, Somerset

    Registered: 15 Jun 2006

    Posts: 10,305

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    Post #6
    Whilst you are there you may as well IMO, or at least replace the firing ring as you don't really want to have to take it all apart again if it blows at the joint.

    My preference is to lay with my legs sticking out the front - but please do use axle stands, wheels underneath, have supervision if poss etc etc. I know someone who died from having a car fall on him, and when you are wiggling things around you don't want to risk it toppling on top of you.

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  • Senior Test Automation Engineer for the 306GTi6 Owners Club Forum Wizard

    • Posted 17th Nov 2014 at 18:20
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    barrym

    Senior User

    Location: Westcliff-on-sea

    Registered: 26 Jun 2014

    Posts: 502

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    Post #7
    yeah I have all the kit, will have the car on axle stands under the front subframe and another set under the sills, chocks behind the rear wheels etc.

    I would like to go with a fitting kit, and will pop into my Pug dealer tomorrow to check availability. If I can get one I will use it but I HAVE to fit this Wednesday. Even if just as a temporary measure till i get the time to do a 100% proper job.

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    China D Turbo HDi daily charger
    Black Rallye occassional toy
    Posted 17th Nov 2014 at 18:31
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    dangti6

    aka JKshooter

    Location: Taunton, Somerset

    Registered: 15 Jun 2006

    Posts: 10,305

    Status: Offline
    Post #8
    You can buy the firing ring singly from a motor factors/eBay even.

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  • Senior Test Automation Engineer for the 306GTi6 Owners Club Forum Wizard

    • Posted 17th Nov 2014 at 18:33
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    barrym

    Senior User

    Location: Westcliff-on-sea

    Registered: 26 Jun 2014

    Posts: 502

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    Post #9
    Cheers, I will check local availability.

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    China D Turbo HDi daily charger
    Black Rallye occassional toy
    Posted 17th Nov 2014 at 18:37
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    demondriverdan

    Seasoned Pro

    Location: Londinium

    Registered: 29 Nov 2010

    Posts: 2,665

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    Post #10
    It's worth getting a fitting kit while you're there really. It's about £20 but makes life easier if you have to change the cat again as you know the kit will be new.

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    Rallye Race Car
    Posted 17th Nov 2014 at 18:52
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    ian7675

    Techno Viking

    Location: Gloucestershire

    Registered: 12 Oct 2007

    Posts: 6,068

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    Post #11
    I would advise getting the full kit, if you take the original bolts/springs off and lose one then you're stuffed. It's a simple job but as already said its fiddly. And definitely use goggles as Dan said. The kit comes with different sized bolts so it's just a case of matching the right ones to the originals.

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    Less than 24 hours to go!
    Posted 17th Nov 2014 at 18:55
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    barrym

    Senior User

    Location: Westcliff-on-sea

    Registered: 26 Jun 2014

    Posts: 502

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    Post #12
    New cat is now in place and car is fine again!

    As stated it is a fiddly job but not complicated. Thanks for the help guys Thumbs up

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    China D Turbo HDi daily charger
    Black Rallye occassional toy
    Posted 20th Nov 2014 at 15:47
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