How 2: Put A Catalytic Converter On An EP91

[NightSpirit]

Actually real easy job...took me about 2 hours in the rain

What you'll need:

socket set with long extension and medium extension, 10mm, 12mm and 14mm socket.

Drill with 32mm or similar wood bit...

or a nice big hammer and chisel

Basically, make sure you're wearing protective goggles and a face mask (cats are nasty things).

Jack the car up and make sure it's secure on axle stands or similar then get under the car and get ready for some stress relief.

Firstly, remove both sides of undertray (the ones attached to the front bumper that go to the base of each wheel arch..there are 4 10mm screw/nuts holding these on.

Next up, remove the heatshield from the base of the cat, this is the awkward bit as the screws are rusty and one is in a crap position. There are 4, 2 at the bottom and 2 at the sides. With this off you should be able to move it in an angle to the passenger side of the car and remove it. (10mm)

Next up disconnect the sensor from the cat, it's a simple 2 wire connector so no problem there.

Now remove the 4 14mm bolts that hold on the cat to the front of the exhaust, the base of the cat is square one bolt at each corner.

Finally remove the 2 12mm bolts that hold the front part of the exhaust in place, when this is done you should see the picture below...moving the exhaust out of the way and securing it on the gearbox/bell housing passenger side.

Now you can get to work breaking the cat up...this is why you need the mask as the powdered ceramic isn't good for the lungs. Once you've broken up a bit of the cat, you should find you can pull the rest out (it's held in place with a metal mesh round the sides..it should all come out in one go).

Now you just need to make sure all the metal rings are out and the top rings are out (put your hand into the cat and feel for them if they haven't fallen out already)...and bolt it all back up.

Enjoy improved spooling of the turbo and a slight increase in turbo pressure (I found).