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        General >> Give/Need advice to/from others >> Separating cat from exhaust manifold...
        
(Message started by: tlundkvi on Dec 30^th, 2008, 6:52pm)

Title: Separating cat from exhaust manifold...
Post by tlundkvi on Dec 30^th, 2008, 6:52pm

Hi all,

Still trying to get the cats replaced. Had it at the workshop today, but they had to give up, as the nuts sat too hard, and they were afraid to break the exhaust manifold. They did not have access to precise gas burners etc.

Did not have a chance to look myself, how does the surface bolt mount facing down in the manifolds look like from up? If intense heating does not release the nuts, is it safe to cut the bolts, drill holes through the old bolt (from under?) and install generic nuts+bolts?

All tips+tricks are welcome!

Title: Re: Separating cat from exhaust manifold...
Post by Highlander on Dec 30^th, 2008, 6:59pm

Tried running the engine first till its hot?

Title: Re: Separating cat from exhaust manifold...
Post by tlundkvi on Dec 30^th, 2008, 7:07pm

The opposite actually, I was told to come early so it has time to cool off, obviously the first mistake.

Title: Re: Separating cat from exhaust manifold...
Post by Highlander on Dec 30^th, 2008, 7:15pm

They'll come off easier if its hot, admittedly they then wont be able to touch it till it cools down though :)

Title: Re: Separating cat from exhaust manifold...
Post by tlundkvi on Jan 2^nd, 2009, 4:36pm

But will I need to start looking for a new manifold if the surface bolt in the manifolds break (twists off etc.)?

Title: Re: Separating cat from exhaust manifold...
Post by Highlander on Jan 2^nd, 2009, 5:47pm

Oh that sounds like a female talking!! what if what if what if :)

The manifold does not have a threaded parts or any captive nuts, just 4 holes for the cat bolts to pass through.

If they shear the manifold will be ok

Title: Re: Separating cat from exhaust manifold...
Post by tlundkvi on Jan 2^nd, 2009, 6:23pm

on 01/02/09 at 17:47:47, Highlander wrote:

The 24V manifolds do have 2 surface mounted bolt ends each. What I can guess from pictures though, I'd guess they can be cut, and the mount drilled through from above to create bolt holes. Yes, admit I sound paranoid, but a new/used exhaust manifold is rare to find in Finland, if it breaks it'll take min. a week to get a new from abroad.

Here's the picture I found:
http://www.jackscarparts.co.uk/images/1962.JPG?osCsid=1a9ci01aamjb4tuis2ttvafgp5

Title: Re: Separating cat from exhaust manifold...
Post by Highlander on Jan 2^nd, 2009, 7:54pm

Sorry I was thinking it was a 16v, still nearly the same thing, worst scenario a broken stud which should be easily replaced, i wouldnt expect they would manage to damage the manifold by taking the bolts off but you never know ;)

Title: Re: Separating cat from exhaust manifold...
Post by cossie_al on Jan 2^nd, 2009, 10:12pm

When I did mine the studs did snap. Had to remove the manifolds to drill drill them out.
Nuts and bolys worked just fine :D

Title: Re: Separating cat from exhaust manifold...
Post by tlundkvi on Jan 12^th, 2009, 8:04pm

The car has now got new cats installed. Technique used was conservative using rust solving agents. The right cat was worse stuck, it was really close they gave up on it, but removing the manifolds knows even more work and 12 more seized nuts to work through. CO went down to 0.1, and HC to 45ppm, which is quite high for fresh cats. Probably because I left the old lambda sensors in (see below for the stinginess). That could also explain a 0.2 O2, unless there is a small leak somewhere. Lambda value was a perfect 1.003. Almost identical values were recorded both on idle and revs.

Cost: 10 workshop hours + 193 GBP for the cats. Means 7 hours active work to remove 7 seized nuts.

You should have seen me then when I was driving away from the parking lot when I noticed something caused a weird noise in the steering. Fortunately only the LHS manifold shield had bent out to make contact with the steering rod joint, easily fixed, lucky me.

So the registration MOT passed, and let's hope it passes the next without surprises. Crap, they didn't even double check the emission test themselves at the MOT, would have got away with a test from a Fiesta. Probably how the German MOT from 03/2008 passed.