Well Blocked Catalytic Converter

[addo]

Oh yes, at 236K (kilometres) the "cat" has failed.

Naturally, it failed mid-roadtrip so I limped the last 800 miles home at speeds down to 25MPH, smelling too-hot 4711 from the gearbox as it revved its tits off in second up hills, and the temperature gauge loved to climb precipitiously whenever in second.

I can hear the cat rattling; it has further done its damnedest to expel the wire gasket from the manifold in an effort to improve flow. All I need is a full day to gut it, and make sure everything else is tickety-boo. Finding it hard to source a universal fit converter that's a suitable size for the proper repair; most are too small or rather dear for dubious quality.

PSA want 958 Euro HT, sans livraison en Australie.

[jgra1]

bad news adam, glad you got back ok..

let me know if I can do anything
J

[addo]

Err... Hold the ring spanner on the top head of the flange bolt?

I'm trawling Fleabay UK (naturally) for NOS/surplus genuine cats. Anything over £650 will attract tax when it lands.

Map Link.

[jgra1]

yeah i know that bolt

some journey .. quite a big block of rock really.. esp when you see a little blue line in a corner of it, which equates to a 5 day bike trip for me in a part of europe..

[handyman]

Addo, you're not trying to undo those manifold flange bolts are you? Only way is to either saw through them or a dab of heat on the nut and them wiz them off with a suitable wizgun. I'm buying in some new ones as stock spares, want me to send you a couple?

PM me if you get stuck on the cat.

H

[addo]

Merci, Homme-de-main. I've got a couple of pattern spares, but in the past have averaged a 75% success rate with unscrewing the originals. Even the constricting band clamps for the middle and rear sections are wholly free and reusable here. Still, dropping the whole exhaust is a bugger of a job to do on the kerbside - which is where I first tried it.

Have to say, the 12V PRV XM/605 cat looks awfully similar in box dimensions and pipe sizes.

[Deanxm]

Just buy any old cat with the right size pipework and weld it in to your pipes if they are not rusted at all, its a little faff but potentialy a big money saver. although too small in diameter i would think this is the sort of thing im on about http://www.ebay.co.uk/itm/REACT-Catalyt ... 46000cff85" onclick="window.open(this.href);return false;

D

[addo]

Of the "universal" cats, I think this is one of the closer spec units by physical size: http://www.summitracing.com/parts/mpe-94435/overview/" onclick="window.open(this.href);return false; - It also has the bung in a similar spot to OEM.

My greatest worry about a genuine one, is it getting trashed during airfreight.

[addo]

Temporary fix (gutting) done; new oxygen sensor fitted as well. 50% success on the bolts; one had clearly been rounded off on the top before.

Definitely less pedal required for progress!

My reassembly hint for novices without an offsider or hoist:

Cut some lengths of ½-¾" metal tubing, the first being about an inch long, then stepping up in quarters to about 1½" Fit the shortest one with a disc washer to one side of the joining flange over the securing bolt, as a temporary holder. Then "toggle" between sides until the longest one may be secured with a thread or two on the nut. Tighten it well to draw the bolt's shouldered collar home in the manifold. Now remove it and fit the first washer/spring/cup set lightly threaded on. Repeat process for other side.

[CitroJim]

So you've now de-catted yourself then Adam

How will that affect your equivalent of the MOT?

Gosh knows how to pack a cat for airfreight... My new one arrived bare in a plastic bag. It seemed to survive OK.

Good tip on getting those pesky bolts done up. Often a jack under the cat will provide enough up force to set it on the brillo pad well enough to be able to reassemble. A bit of grease to help all the bits stay together can help too...

[addo]

I do my own MOTs, but they're signed off by a mate. It's currently non-compliant with a decat but there's no mandated testing - it's visual and you don't have to lift the car...

Knowing there's greater levels of CO swirling around the tailgate, makes me nervous - I run without a tailgate seal.

What I should add about the cat, is, the outlet end appeared perfect. The front half was all smashed up, loose and dodgy. I'm wondering if the harsh shifts of an AL4 shortened it's life with numerous severe jolts.

[citroenxm]

you mentioned PRV 12V cats being simmilar... Ive a fair few of those lieing around in sheds adam if you decide one will do..

$500 owt to do it nicely with free postage...

[addo]

They're slightly different - I had the two side by side for comparison. The PRV cat turns up at the nose subtly and has no longitudonal divider in its inlet.

At a pinch you could "cut and shut", though.

[addo]

I've been waiting for the exuberance that comes with newfound power, to abate. Now it reasonably has, I can report up to an extra 7% mileage per tank for an unrestricted exhaust.

[Mandrake]

Only 7% ??