Cat Replacement On Mk1 1.9tdi

[nogdog]

Well as you will see from the pics the cat on my wifes Mk1 split off at the pipe weld.

 

Replacement was pretty straight forwards:

 

1) Make sure the exhaust is stone cold. ( a ) so you don't burn your hands and ( B ) so everything is free to move and not expanded.

 

2) Remove the 3 flange bolts. Mine were 10mm forward of the flange with 13mm nuts. One had to be cut off with the grinder because the head had rusted through.

 

3) Remove the U-clamp from the rear tail section and joggle out the pipe.

 

Once out fit the new cat into the rear pipe first and then mate up with the flange, not forgettting to put the new gasket and seal into the flange that came with your new cat and copper grease on the new bolts.

 

GSF part number 21515 comes with the flange in the bag with the cat along with new copper nuts and steel bolts for the flange end. Price when I purchased mine today by going in and being cheeky enough to ask for discount.

Edited May 26, 2009 by nogdog