#1: Problem re-fitting Catalytic converter - NOW SOLVED Author: CluelessMike, Location: WalesPosted: Tue Mar 04, 2014 7:41 pm ---- Hi all
Registered ages ago but have always found the answers to my previous problems by searching the really helpful forums here so never needed to post before.
Anyway I decided to attempt to replace my damaged Catalytic Converter on the weekend on my 2004 1.4 206. Did my research on all the potential problems such as seized bolts and removing the Lambada sensor. Gave everything a drenching with penetrating oil and was pleasantly surprised at how easily I got the old CAT off. Then the nightmare began.
I could not get the down pipe from the new CAT to sit flush with the centre pipe on the main exhaust no matter what I tried. I assumed that the centre piece must have also been damaged along with the CAT and so bought a new one of those yesterday. This time the join was even worse and I couldn't get the two parts even close.
Tonight I took off the CAT and the centre pipe and brought them inside to check what the problem is. Basically I am now really puzzled as what I have been trying to achieve while laid under the car, looks like it isn’t possible (that being the two parts sitting flush together).
So my question is this: Should the two brackets that fit the CAT and the centre pipe together have a flush fitting or is it supposed to have a visible gap between them? As the old CAT down pipe has hit a speed-bump at some force it is in a mess and was mangled so couldn't use that as an example.
If they are supposed to sit flush (as would appear sensible when trying to create an air tight join) then I have something seriously wrong with the CAT I purchased as neither the old or new centre pipe get anywhere near sitting flush at all.
Any help from anyone would be greatly appreciated as I am losing the plot a bit with this as what I thought would be a couple of hours job, is now spilling in to day 4 and I am still no closer and still getting the bus to work !!
As an aside I thought it was strange that the new CAT didn't come with a gasket for the connection to the manifold. I asked at point of purchase and they said they didn't think there was supposed to be one. There is a sort of metal gasket already still in place but wonder if I also need to source a gasket or not as the CAT supplier was not very helpful and research online is inconclusive as to whether there is such a thing or whether one is needed?!?!
Many thanks in advance
Mike Last edited by CluelessMike on Tue Nov 11, 2014 6:09 pm; edited 1 time in total
#2: Re: Problem re-fitting Catalytic converter - exhaust problem? Author: lukepug19, Location: OxfordshirePosted: Wed Mar 05, 2014 1:20 am ---- the only gasket you should have between the cat and centre pipe is a round metal ring that sits between the two pipes. the two pipes should not be touching because of the metal ring gasket is quite thick. then all you should have is the two bolts two springs two washers and two nuts and tighten. because and I maybe wrong and someone on here will soon correct if im not but you the gap and the springs going over the bolts is cause the join acts almost like a flexi
#3: Re: Problem re-fitting Catalytic converter - exhaust problem? Author: Seatock789, Location: MorecambePosted: Wed Mar 05, 2014 1:40 am ---- Check out:- www.reactcatalysts.co.uk, input your reg.no and then select exhaust systems. This should give you a diagram of the exhaust system. There is meant to be a gasket between the cat & manifold. I ended up taking the whole exhaust system off and then started re-fitting from the front back. There is also meant to be a conical gasket that sits between the cat & link pipe.
Is it possible that when you hit the speed bump you've knocked something out of alignment.
If you where closer I'd give you a hand. Last edited by Seatock789 on Wed Mar 05, 2014 11:31 am; edited 1 time in total
#4: Re: Problem re-fitting Catalytic converter - exhaust problem? Author: macca1411, Location: Westhoughton, LancashirePosted: Wed Mar 05, 2014 3:26 am ---- If you get a fitting kit, then it should come with the manifold to cat gasket, new nuts, an O ring for the centre pipe connection and new bolts and springs for the clamp. Use some muffler assembly paste on the centre pipe connections, but don't put any on the cat to manifold connection.
The cat/downpipe should only sit in one place because of the bolt that holds it to the gear box. Once that is fitted, place the back box on the hangers and then offer up the centre pipe. Loosely fasten the centre pipe to the back box and then connect up the front of the centre pipe to the down pipe. Doing it this way means you can get the alignment of the exhaust right. Unlike the numpties who did mine before I got the car. They put the back box and centre pipe together first, and then when they had to connect it to the downpipe, it threw the backbox out of alignment.
#5: Re: Problem re-fitting Catalytic converter - SOLVED Author: CluelessMike, Location: WalesPosted: Tue Nov 11, 2014 6:07 pm ---- I thought I had posted a conclusion to this thread at the time but on logging back in today, it seems I didn't??
Anyway many thanks to the 3 of you who took the time to reply back in March, it was very helpful and much appreciated!!
It was the round metal ring that was missing so thanks for the advice.
Had to go to a few places but got one in the end as part of a fitting kit from Euro Car Parts and it all went together like a dream after that.......if only I'd posted on here sooner instead of spending every night trying to look for the answer online.
I checked the old CAT once I knew what I was looking for and the reason I had not noticed it, is because it was so badly bashed that the metal ring looked like it was part of the CAT itself......sort of mangled together.
So thanks again and if anyone else has this same problem, hopefully Google will lead them to this thread and save them a lot of time!
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