Bruunz

It doesn't seem to be readily available in Australia would this be a better option than WD-40?

Permatex Fast Break Super Penetrant - 340g - Supercheap Auto

Bruunz

Thanks! i'll pick one up on the weekend.

Chris_Lum

WD-40 makes a PB blaster style penetrant spray too: https://wd40specialist.com/products/penetrating-oil/

but any penetrant spray would probably be fine.

Chuck S

Yep, a penetrating oil is what ya need.

Weekend is over in Oz. (I never worry about tomorrow 'cuz it's always tomorrow in Australia!) Any progress?

-- Chuck

Car Analogy

Yeah, lube the heck outta cat bolts when reassembling. Make next time easy...

Bruunz

No progress. Didn't even purchase the 02 sensor socket.
A combination of cold / wet weather, couch time with GT:Sport (and the GF letting me play) and and endless list of excuses to not do it.

Gonna give it a crack next Saturday however its my birthday this week so i might have to battle a hang over.

Chuck S

Start spraying the bolts and nuts with penetrating oil.

-- Chuck

Bruunz

Update:

I GOT THE CAT OUT!!!! What a huge PITA but all the bolts eventually broke loose. Funnily enough that was actually the easiest part. Removing the secondary 02 sensor clip was more painful. i felt like the access was designed for children but i eventually got it before my hand got a cramp.
I kept the rest of the exhaust in and removed the CAT however i think this wasn't the best idea. I was lucky to get enough stretch in the hangers but i needed the angle and pulling force to be right.

The removal took about 90 minutes. I was absolutely buggered after that.

I kept the secondary O2 sensor in the original CAT thinking it would be easier to remove once the CAT was out.... another mistake. I've let it sit with penetrate in hopes to remove it tonight. I don't need to remove it but i thought i would practice on this before i attempt to remove the primary which has less accessibility.

When i removed the original CAT, there was a large knocking inside of it like a cue ball moving about. I believe this is a sign for a faulty CAT. So im quite happy i preempted this possibility and got myself a Berk HFC. I just wish the berk would allow me to use the heat shield.

Things left to do:

Remove secondary 02
Remove primary 02
Install new primary 02
Install HFC
Install secondary 02
Figure out how to reuse the clips for the sensors
Connect battery again let ECU relearn

Bruunz

New Update:

New HFC is in. The bolts supplied with the berk i believe were imperial lucky a 17mm managed to do the job.
Installed the new secondary O2 without a hitch.
I dont know what it is with the O2 connectors but they are the worst!!! I managed to loosen the primary 02 without a problem but i then proceeded to spend 30mins trying to disconnect it..... Connecting was all good other than trying to get the sensor to start the thread. I just couldn't see where i was putting it so i had to fiddle with it.
Im going to need some cable ties to replace clips and i should be all done. I will probably clean the IAC while im at it.

Bruunz

Last Update:

I am so happy i did this. I had no idea that my CAT was the source of so many issues. My car is now quieter with the Berk HFC which makes the GF happy. I thought i had some drive line rattles and sounds but now see it was the CAT all along. Additionally i feel like i have picked up a lot more low end response and torque.
Judging from the rattle that is no longer present i, i think i had a broken CAT for almost 2 years........ I thought it was a clutch / thrust bearing sound this whole time...

The IAC has been cleaned out but i didn't have the correct TORX (apparently a t20h isn't the right one??? i found a link in video that refers to a 20IPR.. whats the difference?) bit to remove the motor and thoroughly clean it. I'll save this for another time when i clean the TB.