Dr HMS Derv Destroyer
ClioSport Club Member
MK1DTi/vivaro/corsa
Hi all, I have put together a little guide for anyone wanting to remove/ de-catt a dCi . ** please note, this is for the mk2's only **
some bits maybe slightly different, BUT following these
clio dCi mk2 cat removal ( de-catt procedure )
> whilst car is on the ground, crack off ( loosen ) drivers side hub nut and wheel bolts
> jack car up and place front end high on 2 axle stands ( if placing on sills, please use something with a groove in to prevent damage )
> remove wheel
!drive shaft removal !
two ways of doing this bit:
method 1:
> undo track rod end nut ( nut that holds this to the hub ) and let track rod end and arm hang.
> undo both lower strut bolts ( 2 bolt and nuts holding hub to shock ) ** take note which way around these go, ie nut which side **
> carfully push down hub , with care as brake lines are still attached, and pull out the drive shaft after fully removing hub nut.
> using something ie a crow bar, or blunt chissel , place bettween drive shaft and gearbox housing, gently prise drive shaft out ( no fluid should come out ) ** once drive shaft starts to come away, pull the rest off by hand **
method 2 :
> undo track rod end nut ( nut that holds this to the hub ) and let track rod end and arm hang.
> undo lower ball joint pinch bolt, remove with a punch tool and hammer, care to be taken to not f**k up the threads ( unless changing the bolts for new ones )
> hit the wishbone with a hammer and piece off wood. wishbone-wood-hammer. until ball joint is seperated from hub.
> undo the hub nut fully, the pull hub towards you and remove drive shaft from hub unit
> using something ie a crow bar, or blunt chissel , place bettween drive shaft and gearbox housing, gently prise drive shaft out ( no fluid should come out ) ** once drive shaft starts to come away, pull the rest off by hand **
! Exhaust and cat retaining bracket !
> underneith the car, you will see the join from cat to exhaust, held by two nuts/studs ( 13/12mm ) remove these two nuts and pull exhaust away ( DONOT lose the metal gasket that will fall out the joint ) and one bolt from cat bracket to exhaust ( not every dci has this )
> torch/ inspection lamp maybe needed for this bit.... whilst still underneith, you will see a bracket around the cat, this is held on by 3/4 PLUS the bolt that attaches cat bracket to the exhaust ( not every dci has this ) bolts are 13mm , 2 on the side of cat, and 1/2 on engine block. remove these and take cat bracket off.
! UP top in bay !
> jack engine up a little with a piece of wood bettween jack and sump ( assuming you dont have a dirt shield underneith ) basicly just supporting the load
> remove top left engine mount, four bolts around bottom to shell, 3/4 long bolts on mount to engine. ** do not over jack as bolts will not come out easy , if so let jack down a little until the engine is still supported **
> remove EGR metal boost pipe, held in by one 13mm bolt on rear, then pull pipe off ( pipe has two rubber seals, do'not damage these )
> using anything suitable to wedge bettween engine and bulk-head ( block of wood ) , move engine forward, not to heavy handed or the alternator/ aircon or oil filer may damage rear face of rad assembly.
> now you will see 4 nuts and studs, holding cat to turbo outlet. these can be tricky to do but still all accessable. 10 mm nuts. some of them may come out with the stud, but not to worry. use a combination of deep sockets/ extensions and spanners to remove these. ** please not some of them will be tight due to the metals constantly being heated through use **
! your cat should now be ready for removal !
> pull away from turbo housing, ** be carefull as brake fluid tank is just bellow **
> handle it down onto the sub frame or with help from someone else , pass it to them.
> rotate onto side and send out through the gap of where you drive shaft was.
De-catt at your hearts content
**** REFITTING ****
> place cat back in place, and do the cat to turbo bolts back up first!
> the rest is simply the reverse of removing
please note, I do not take any responsibility for damaged caulsed to your car when doing this job
some bits maybe slightly different, BUT following these
clio dCi mk2 cat removal ( de-catt procedure )
> whilst car is on the ground, crack off ( loosen ) drivers side hub nut and wheel bolts
> jack car up and place front end high on 2 axle stands ( if placing on sills, please use something with a groove in to prevent damage )
> remove wheel
!drive shaft removal !
two ways of doing this bit:
method 1:
> undo track rod end nut ( nut that holds this to the hub ) and let track rod end and arm hang.
> undo both lower strut bolts ( 2 bolt and nuts holding hub to shock ) ** take note which way around these go, ie nut which side **
> carfully push down hub , with care as brake lines are still attached, and pull out the drive shaft after fully removing hub nut.
> using something ie a crow bar, or blunt chissel , place bettween drive shaft and gearbox housing, gently prise drive shaft out ( no fluid should come out ) ** once drive shaft starts to come away, pull the rest off by hand **
method 2 :
> undo track rod end nut ( nut that holds this to the hub ) and let track rod end and arm hang.
> undo lower ball joint pinch bolt, remove with a punch tool and hammer, care to be taken to not f**k up the threads ( unless changing the bolts for new ones )
> hit the wishbone with a hammer and piece off wood. wishbone-wood-hammer. until ball joint is seperated from hub.
> undo the hub nut fully, the pull hub towards you and remove drive shaft from hub unit
> using something ie a crow bar, or blunt chissel , place bettween drive shaft and gearbox housing, gently prise drive shaft out ( no fluid should come out ) ** once drive shaft starts to come away, pull the rest off by hand **
! Exhaust and cat retaining bracket !
> underneith the car, you will see the join from cat to exhaust, held by two nuts/studs ( 13/12mm ) remove these two nuts and pull exhaust away ( DONOT lose the metal gasket that will fall out the joint ) and one bolt from cat bracket to exhaust ( not every dci has this )
> torch/ inspection lamp maybe needed for this bit.... whilst still underneith, you will see a bracket around the cat, this is held on by 3/4 PLUS the bolt that attaches cat bracket to the exhaust ( not every dci has this ) bolts are 13mm , 2 on the side of cat, and 1/2 on engine block. remove these and take cat bracket off.
! UP top in bay !
> jack engine up a little with a piece of wood bettween jack and sump ( assuming you dont have a dirt shield underneith ) basicly just supporting the load
> remove top left engine mount, four bolts around bottom to shell, 3/4 long bolts on mount to engine. ** do not over jack as bolts will not come out easy , if so let jack down a little until the engine is still supported **
> remove EGR metal boost pipe, held in by one 13mm bolt on rear, then pull pipe off ( pipe has two rubber seals, do'not damage these )
> using anything suitable to wedge bettween engine and bulk-head ( block of wood ) , move engine forward, not to heavy handed or the alternator/ aircon or oil filer may damage rear face of rad assembly.
> now you will see 4 nuts and studs, holding cat to turbo outlet. these can be tricky to do but still all accessable. 10 mm nuts. some of them may come out with the stud, but not to worry. use a combination of deep sockets/ extensions and spanners to remove these. ** please not some of them will be tight due to the metals constantly being heated through use **
! your cat should now be ready for removal !
> pull away from turbo housing, ** be carefull as brake fluid tank is just bellow **
> handle it down onto the sub frame or with help from someone else , pass it to them.
> rotate onto side and send out through the gap of where you drive shaft was.
De-catt at your hearts content
**** REFITTING ****
> place cat back in place, and do the cat to turbo bolts back up first!
> the rest is simply the reverse of removing
please note, I do not take any responsibility for damaged caulsed to your car when doing this job
