Blocked Catalytic Converter on VW T4 2.5 Tdi

Last week my turbo started howling like a police siren. It turned out to be
dead at 100,000 kms. My friendly VW dealer replaced the turbo and VW paid
(reluctantly) for half the cost of the parts. This week it has only a
fraction of the mid-range grunt that it used to have. It is quite a chore to
drive it.
So, I went back to the dealer to have it inspected. After a quick test drive
around the block the diagnosis is "the cat is blocked with coke". It seems
that the intake manifold was coated in coke and, when it was disturbed, some
worked its way thru the engine into the cat where it now resides.
A new cat (genuine VW) costs $2700.
My friendly VW dealer does not want to help me any more other than telling
me what went wrong and offering me the $2700 cure.
Any ideas?
Bill

Bill Stoney wrote:
> Last week my turbo started howling like a police siren. It turned out to be
> dead at 100,000 kms. My friendly VW dealer replaced the turbo and VW paid
> (reluctantly) for half the cost of the parts. This week it has only a
> fraction of the mid-range grunt that it used to have. It is quite a chore to
> drive it.
> So, I went back to the dealer to have it inspected. After a quick test drive
> around the block the diagnosis is "the cat is blocked with coke". It seems
> that the intake manifold was coated in coke and, when it was disturbed, some
> worked its way thru the engine into the cat where it now resides.
> A new cat (genuine VW) costs $2700.
> My friendly VW dealer does not want to help me any more other than telling
> me what went wrong and offering me the $2700 cure.
> Any ideas?
> Bill
>
>

They fucked it
they fix it.

generic aussie made cat $250 at any exhaust shop, probably better than the
one it came with too.


"Bill Stoney" <billstoney@hotmail.com> wrote in message
news:wXnfd.550$%I1.149@news-server.bigpond.net.au...
> Last week my turbo started howling like a police siren. It turned out to
> be dead at 100,000 kms. My friendly VW dealer replaced the turbo and VW
> paid (reluctantly) for half the cost of the parts. This week it has only a
> fraction of the mid-range grunt that it used to have. It is quite a chore
> to drive it.
> So, I went back to the dealer to have it inspected. After a quick test
> drive around the block the diagnosis is "the cat is blocked with coke". It
> seems that the intake manifold was coated in coke and, when it was
> disturbed, some worked its way thru the engine into the cat where it now
> resides.
> A new cat (genuine VW) costs $2700.
> My friendly VW dealer does not want to help me any more other than telling
> me what went wrong and offering me the $2700 cure.
> Any ideas?
> Bill
>

I'm sure you could fit a non factory cat ? see a local exhaust shop. Check a wrecker,
see if perhaps you can get one cheap.


"Bill Stoney" <billstoney@hotmail.com> wrote in message
news:wXnfd.550$%I1.149@news-server.bigpond.net.au...
> Last week my turbo started howling like a police siren. It turned out to be dead at
> 100,000 kms. My friendly VW dealer replaced the turbo and VW paid (reluctantly)
> for half the cost of the parts. This week it has only a fraction of the mid-range
> grunt that it used to have. It is quite a chore to drive it.
> So, I went back to the dealer to have it inspected. After a quick test drive around
> the block the diagnosis is "the cat is blocked with coke". It seems that the intake
> manifold was coated in coke and, when it was disturbed, some worked its way thru
> the engine into the cat where it now resides.
> A new cat (genuine VW) costs $2700.
> My friendly VW dealer does not want to help me any more other than telling me what
> went wrong and offering me the $2700 cure.
> Any ideas?
> Bill
>

That suxs! Whats with 1/2 the cost if its still under warrant and take it
back if its a pox job!

I wont bother saying keep away from WAY overpriced and underdone
German/European junk :-))

In any case head down to Midas and/or similar with a slab of VB, get the
dudes to cut in front and behind the CAT and weld in a straight piece of
pipe so u remove the CAT for good.

Problem solved, cost approx $100

Good luck

CDIHL [Very very satisfied Ford Transit Tdi & Kia Pregio DIEsel buyer :-))


"Bill Stoney" <billstoney@hotmail.com> wrote in message
news:wXnfd.550$%I1.149@news-server.bigpond.net.au...
> Last week my turbo started howling like a police siren. It turned out to
be
> dead at 100,000 kms. My friendly VW dealer replaced the turbo and VW paid
> (reluctantly) for half the cost of the parts. This week it has only a
> fraction of the mid-range grunt that it used to have. It is quite a chore
to
> drive it.
> So, I went back to the dealer to have it inspected. After a quick test
drive
> around the block the diagnosis is "the cat is blocked with coke". It seems
> that the intake manifold was coated in coke and, when it was disturbed,
some
> worked its way thru the engine into the cat where it now resides.
> A new cat (genuine VW) costs $2700.
> My friendly VW dealer does not want to help me any more other than telling
> me what went wrong and offering me the $2700 cure.
> Any ideas?
> Bill
>
>

Just cut the old one off carfully and install a striaght through pipe and
reweld the old cat over the top! Will never get clogged again and may
increase power adn fuel economy, mind you, you run the risk of a fine of you
are ever (highly unikely) caught.

Total job likely to be around the $50 mark.



"What The" <meh@meh.com> wrote in message
news:k_ofd.603$%I1.398@news-server.bigpond.net.au...
> I'm sure you could fit a non factory cat ? see a local exhaust shop. Check
> a wrecker, see if perhaps you can get one cheap.
>
>
> "Bill Stoney" <billstoney@hotmail.com> wrote in message
> news:wXnfd.550$%I1.149@news-server.bigpond.net.au...
>> Last week my turbo started howling like a police siren. It turned out to
>> be dead at 100,000 kms. My friendly VW dealer replaced the turbo and VW
>> paid (reluctantly) for half the cost of the parts. This week it has only
>> a fraction of the mid-range grunt that it used to have. It is quite a
>> chore to drive it.
>> So, I went back to the dealer to have it inspected. After a quick test
>> drive around the block the diagnosis is "the cat is blocked with coke".
>> It seems that the intake manifold was coated in coke and, when it was
>> disturbed, some worked its way thru the engine into the cat where it now
>> resides.
>> A new cat (genuine VW) costs $2700.
>> My friendly VW dealer does not want to help me any more other than
>> telling me what went wrong and offering me the $2700 cure.
>> Any ideas?
>> Bill
>>
>
>

or if you want to spend zero $$'s take the cat out yourself and hammer
out all the inside honeycomb stuff and re-install. much more free
flowing! turbo's love that extra flow!

But yeah it's illegal and it pollutes more.

"Ziggy Switkowski" <Ziggy@telstra.com> writes:
>"Bill Stoney" <billstoney@hotmail.com> wrote in message
>news:wXnfd.550$%I1.149@news-server.bigpond.net.au...
>> Last week my turbo started howling like a police siren. It turned
>> out to be dead at 100,000 kms. My friendly VW dealer replaced the
>> turbo and VW paid (reluctantly) for half the cost of the parts.
>> This week it has only a fraction of the mid-range grunt that it
>> used to have. It is quite a chore to drive it.

>> So, I went back to the dealer to have it inspected. After a quick
>> test drive around the block the diagnosis is "the cat is blocked
>> with coke". It seems that the intake manifold was coated in coke
>> and, when it was disturbed, some worked its way thru the engine
>> into the cat where it now resides.

>> A new cat (genuine VW) costs $2700.
>> My friendly VW dealer does not want to help me any more other
>> than telling me what went wrong and offering me the $2700 cure.

>generic aussie made cat $250 at any exhaust shop, probably better
>than the one it came with too.

For a diesel?

A cat for a petrol engine is designed to work within a narrow
conversion window where there's just enough oxygen, hydrocarbon,
carbon monoxide and nitrous oxides. Put that on a diesel and most of
the time, you'll not get enough HC or CO, and probably quite a bit
too much NOx.

Nett result: it won't work.
--
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