kniff_666 Posted August 4, 2012 Share Posted August 4, 2012 Hello, Currently mid process for removing the cats of my NA (SZ-R, 5spd) and was just wondering what the best way to remove the 1st cat was? Got the rest of the exhaust system off (from first cat back) but it strikes me as extremely difficult to reach the bolts for the cat-to-manifold. I would very much like to avoid taking the exhaust manifold off if it can be helped. If it cannot be helped then how difficult is it to remove the entire exhaust manifold. What torque is on these bolts to the block? How easy is it to get to all the bolts? (currently i have removed the heat shield etc as i am cleaning the O2 sensors) Any help would be great. Quote Link to comment Share on other sites More sharing options...
straightsix Posted August 4, 2012 Share Posted August 4, 2012 Taking the manifold off isn't that difficult and could well be a quicker option especially if you have fat hands! If you really don't want to take it off, just remove the air intake pipework and use some universal joint adapters on your sockets - you might find a ring end spanner easier on a couple of the bolts Give things a spray with Plusgas beforehand to free it all up Quote Link to comment Share on other sites More sharing options...
Scooter Posted August 4, 2012 Share Posted August 4, 2012 I have a 1st decat waiting to go on and have had a look at it and am currently assessing the best way to go about it. Caution is required as there is potential for some major pita scenarios if things start shearing! The 1st cat join to the cast sections are bolts on studs and I would be tempted to see if you can get a socket on the 4. Before proceeding do you have the sockets that fit on the studs, female star/torx type ones? The head/manifold bolts look easier to access and get leverage on, but my stud threads are quite rusty and will need a good clean up first. So I doubt that's much help!! but I'll be interested in how you get on.... Quote Link to comment Share on other sites More sharing options...
straightsix Posted August 4, 2012 Share Posted August 4, 2012 I did all of the with a socket first time around but I laugh in the face of awkwardness. When I took the decat off, I just removed the manifold - loads easier with it all off and on the bench......and you can get the torque wrench on it - - - Updated - - - And Scooter....you'll find that the manifold nuts will come off with the studs on a few - nothing to worry about! Quote Link to comment Share on other sites More sharing options...
thomo8568 Posted August 4, 2012 Share Posted August 4, 2012 Just take the full manifold off, ive done this a few times and it by far the best way. Never had any problems with the manifold to head bolts, but the cat to manifold bolts can be a real PITA. Just put some penetrating oil on first and you shouldn't have any problems. Don't worry if some of the studs come out with the nuts it's just one of them things they will just screw back in. Quote Link to comment Share on other sites More sharing options...
kniff_666 Posted August 5, 2012 Author Share Posted August 5, 2012 Another quick question about this. My decat pipe doesn't seem to have a hole for the bottom sensor to go? What do I do with that sensor? Will it screw up the ecu if I cut it off? Quote Link to comment Share on other sites More sharing options...
thomo8568 Posted August 6, 2012 Share Posted August 6, 2012 It's just the cat temp sensor. My cars never had one and Ive had no problems. But you could just fasten it up out the way to be on the safe side. Quote Link to comment Share on other sites More sharing options...
straightsix Posted August 6, 2012 Share Posted August 6, 2012 Don't cut it off - just tuck it securely out of the way. If you want to remove it, the plug and wiring is under the driver's side footwell carpet but you'll need a rubber grommet to plug the hole in the floor. I think you may have to remove the bulb in the warning light panel too..... So as you see - it's easier to tuck it away somewhere Quote Link to comment Share on other sites More sharing options...
kniff_666 Posted August 6, 2012 Author Share Posted August 6, 2012 I have a 1st decat waiting to go on and have had a look at it and am currently assessing the best way to go about it. Caution is required as there is potential for some major pita scenarios if things start shearing! The 1st cat join to the cast sections are bolts on studs and I would be tempted to see if you can get a socket on the 4. Before proceeding do you have the sockets that fit on the studs, female star/torx type ones? The head/manifold bolts look easier to access and get leverage on, but my stud threads are quite rusty and will need a good clean up first. So I doubt that's much help!! but I'll be interested in how you get on.... Did it by removing the manifold in the end. There was no way i could get to bolts without removing the enitre manifold. This however threw up a different problem. Being able to support / hold the cat and manifolds while removing the bolts. (You do need to use a deep socket to take the nuts off though) Managed to get one side off but did not get round to the other side due to an issue with one of the studs and nuts being cross-threaded and not actually hold the pipes together. (must have been like that since long before i had it) I will be back to continue the saga later. Quote Link to comment Share on other sites More sharing options...
Chris Wilson Posted August 8, 2012 Share Posted August 8, 2012 It's always easiest to pay a mug like me, with a ramp, extensive toll kit and new studs, bolts, nuts, gaskets et al in stock, to do it Quote Link to comment Share on other sites More sharing options...
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