1998 1.9TD Est Catalyst Removal

[Toasted]

Hello All,

I have been living with a 'rattly cat' for some time, but enough is enough, it's got to be looked at!
It was originally purchased from a famous autotcentre beginning with 'K' and lasted just over the 1 year warranty period! - I know what you're gonna say but it was late and I was out of town..... blah, blah, blah!!

Car is a 1998 1.9TD LX Estate

To anyone who has any info on the following (any reply will be really appreciated):

1. Can I replace the existing catalyst section with one from an earlier 'Non-Cat' version? If so, is it a straight, bolt on replacement?
2. If the above was carried out, would it be; detrimental, benefical or make no differance to the cars running/performance?
3. Does anyone know where I can obtain a straight through pipe (no cat or silencer) to fix to the back box? IHowever, I''m thinking it may be a bit noisy/illegal?

Thanks in advance for any replies,

David

[Doggy]

1. Can I replace the existing catalyst section with one from an earlier 'Non-Cat' version? If so, is it a straight, bolt on replacement?

Yes, we did this with my bro's S-reg 1.9TD just after he got it - direct swap, but doing up the front pipe to turbo connection is horrible without a hoist.

2. If the above was carried out, would it be; detrimental, benefical or make no differance to the cars running/performance?

Not sure, no big difference but we think a marginal improvement in both performance and response

3. Does anyone know where I can obtain a straight through pipe (no cat or silencer) to fix to the back box? IHowever, I''m thinking it may be a bit noisy/illegal?

No idea.
If it's any help, my 2.2 HDi has both cat and particle filter elements removed, (though the empty box is still there), so only real silencing is from the back box & I have no noticeable increase in noise. From this I reckon the back box is doing most, if not all of the silencing.

I've heard that the tightened-up MOT will fail a car for having the cat missing, but I think it's vanishingly unlikely anyone would tumble a 1.9 being too 'new' to have a front silencer in place of the cat.

[Toasted]

Cheers for that,
I did see a reply to a post where you mentioned it being done, but wondered whether it was a straight swop with no mods.
Been on the Bosal Catalogue for a cross reference but the downpipe fixing flanges look different???
It's good to hear you've done it though, I've got zero access to any garage facilities anymore, so I'll have to pay the going rate.

Thanks again

[Toasted]

Hello again Doggy,

Just seen that yours is a 2.2hdi and I'm thinking of an change at some point.Love the handling of the old girl so I thought I might look at a later 2.2hdi to get a bit more go. How have you found it, I know they had FAP's which are a bit of a pain, but not the end of the world. Looks like a shed load of torque on paper, must be good to drive?

[Toasted]

Sorry meant to say turbo fixing flanges, not 'downpipe'.

[Doggy]

My 2.2 has had the FAP removed and is remapped to 178 bhp / 295 lb/ft. The standard version seems smooth, quiet & powerful compared to other diesel 406's, but suffers from turbo lag in some oddly unpredictable circumstances. Once converted, it's a different animal.

Having said that, my bro's veg oil-fuelled 1.9 TD does surprisingly well. I imagined the heavier 406 would be slow compared to the 405 he had a few years back, but the more sophisticated management does a brilliant job of enhancing low speed response and tractability, IMHO.

There's obviously a world of difference between the two, but they're both pretty impressive, in different ways.

[D9406]

Earlier this month my cat was stolen, see thieving git thread, and I replaced it with a straight pipe and two sleeve connectors. Result, slightly more average MPG, 48.5 on mfd, was 43, more responsive, turbo spools earlier, power comes in earlier and lasts longer. When motorway cruising, revs lower than before and better MPG, MFD showing 57 mpg at 80 mph steady.
This is on a 110 Hdi though.

[jasper5]

Can I just clarify (again) that the presence of a cat is only required for mot purposes on cars that must have a FULL cat test?

Diesels only have the smoke test.

http://mottesters.co.uk/files/special%2 ... Manual.pdf

Look under section 7.1 exhaust system/method of inspection section 3.

[Toasted]

Cheers for the replies Doggy, thats an impressive sounding car you got there. If I ever did get shot of mine, the 2.2 would be top of the list.
Jasper, thanks also, it's always good to hear it one more time! I was pretty sure that what you mentioned was indeed the case, but after viewing and hearing different opinions on the subject it tends to leave you in a bit of a spin. Good to see the whole truth and nothing but the truth - cheers.

[Toasted]

Cheers D9406, it's nice to hear something good coming out of somethng bad!
Did you buy the straight through pipe off the shelf or was it made to fit?
If it was made to fit, pardon me for asking but, how much are we looking at pricewise?

Cheers

[D9406]

Hi Toasted, The pipe was bought from the local factor for a tenner and I had an stainless steel adapter made to connect a 60mm OD pipe to a 65mm OD pipe for £7.99, Ebay. If you cut close to the cat either side of it you will only need a standard 60mm ID to 60mm ID adapter, I needed a custom because of where they cut my pipe.
With three clamps some firegum job came to about £25. The straight pipe was 500mm long and swaged at one end to 60mm ID, it's a standard pipe, just cut to whatever lenght you need.

[lozz]

why dont you use the original cat, and just bash /clear the insides out
everything looks standard then. nothing needed

[Toasted]

@D9406, cheers for that I will look into it and Lozz good point!

[gumby6371]

Sorry for the hijack but can anyone tell me when they started fitting cat's to the 1.9td engine?
Not been under my new one yet but from what I can see from the side of the car my 1996 model looks more silencer than cat but I haven't had a proper look.

Cheers

Gareth

[Doggy]

I don't know when they changed, but as you say, 96 ones have a front silencer in place of the cat that was definitely being fitted in 98. They're interchangeable.