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Home -> Forums -> Exhausts -> Alternative removal of Cat/Manifold Bolts

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Author Subject: Alternative removal of Cat/Manifold Bolts
rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,990

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Post #1
I expect nothing less of a 20 year old car really but i can't get the bolts undone that connect the cat and the exhaust manifold together. Basically they are just freely spinning, the clever design that's meant to hold the top with the pressure from the spring seems to have failed.

I have managed to get a 10mm spanner on the top end to try and hold the bolt but even that is struggling to get a grip, it's a real seized up nightmare Sad

Has anyone any good ideas on how best to remove these bolts given the access is tough? Id like to just snap them off if i can as i assume new ones will come in the cat fitting kit from pug?

Cheers all.

________________________________________

Just Drive It
Posted 17th Apr 2019 at 18:13
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pug_306

Seasoned Pro

Location: Great Hockham

Registered: 28 May 2013

Posts: 1,592

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Post #2
Hi buddy. Take the cat off from the middle section then push the cat fully one way, while holding it over you can undo the other side nut. Hope that makes sense? I usually use a battery gun too, always works for me Thumbs up

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 17th Apr 2019 at 18:17
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rallyestyle

Seasoned Pro

Location: London

Registered: 23 Jul 2003

Posts: 14,990

Status: Offline
Post #3
Hadn't thought of that one, thanks, will improve access for sure Thumbs up

I'm a little bit worried that it's all seized together though so even with better access to the top nut it's unlikely to come undone. I will get some anti seize stuff on and give it a go.

________________________________________

Just Drive It
Posted 17th Apr 2019 at 19:15
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pug_306

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Location: Great Hockham

Registered: 28 May 2013

Posts: 1,592

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Post #4
Not for better access. When your pushing the cat one way it puts pressure on the bolt so it can't spin :-)

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 17th Apr 2019 at 19:23
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Ben_W

Formerly gpm

Location: Lutterworth

Registered: 01 Sep 2007

Posts: 2,941

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Post #5
They are an utter twat once the bolts have been on a long time. Many heat cycles, wet etc and they are just s**t. The Ph2 Xsara fitting is a much better design and I can't understand why this wasn't used from the start.

Anyway, the method Ryan has mentioned has worked for me in the past. On one car, I got up to the bolts with a Dremel with a cutting disc.,

Yes, the new cat fitting kit has every. Fire ring. Bolts, springs, plates etc

________________________________________

Cherry Red Rallye .... On going OEM spec resto

China Blue GTi6 .... Weekend toy

Black 208 GTi .... Wife's car now

Silver BMW 550i.... The executive missile

Posted 17th Apr 2019 at 20:30
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pug_306

Seasoned Pro

Location: Great Hockham

Registered: 28 May 2013

Posts: 1,592

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Post #6
I have used a P2 VTS manifold on a GTi6 before with a flexi fitted in the downpipe it is a much better design.

________________________________________

1998 Supercharged White Rallye
1992 205 GTi6
205 Turbo 340bhp
Posted 17th Apr 2019 at 20:36
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mocinim

Seasoned Pro

Location: The Darkside of bedford :)

Registered: 09 Jan 2015

Posts: 2,307

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Post #7
Dremmel cutter in the accessible nut it will all just come away then buy the kit on eBay £15 for full kit
Easy done
If you want to use your crusty ones soak them for a day or two with some wd40 or GT85 spray then try again
Dot drive it whilst soaking obviously!!
Definitely advise to replace

________________________________________

BLACK RALLYE - phoenix
WHITE RALLYE - valliant

http://public.servicebox.peugeot.com/

https://www.gov.uk/check-mot-history
Posted 18th Apr 2019 at 00:17
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rallyestyle

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Location: London

Registered: 23 Jul 2003

Posts: 14,990

Status: Offline
Post #8
Thanks for all the tips guys. Will give the Cat removal trick a go and then if all else fails get a dremel on it Yes

________________________________________

Just Drive It
Posted 18th Apr 2019 at 08:40
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