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mpg_numbers_guy · 06-06-2019, 10:53 PM

Thanks! I'll keep that in mind when working on the sound system some more.

Just finished installing the new catalytic converter. CEL codes are all gone except for the hybrid battery one from the dirty bypass I have right now (switch off, BCM unplugged).

Here are the parts I ordered for reference:

Davico Catalytic Converter 58214 {#18194}. Aftermarket catalytic converter that is a direct fit to the Insight and is used by several other Insight owners. Available through Amazon, Ebay, and elsewhere. RockAuto has the lowest price of the three at $208.79. Link here. This catalytic also comes with Honda part #18229-S3Y-J01, which is the exhaust flange gasket to connect the two catalytic converter pipes.
Dorman Pipe to Converter Spring Kit 03416. Also available through Amazon, Ebay, and any Honda parts store. RockAuto had the cheapest price at $3.31 each. 2 are needed. Link here.
Exhaust Manifold Gasket. Honda Part # 18115-PHM-004. This may or may not have been able to be reused, but I went with a new part since I was removing it anyway to install the new catalytic. Price was only $4.22 through the Honda dealership my dad works at. Prices online vary from $4-$10. HondaPartsNow.com and Amazon are two online places that come to mind. RockAuto is/was out of stock at the time of writing this.
Exhaust Manifold Stay. Honda Part # 11941-PHM-000. This is a support bracket that bolts onto the catalytic piping and onto the transmission housing. I replaced mine because it was rusted out. Deleting the support braket will likely make your catalytic conveter break apart at the welds after a while. Price was around $13 through the Honda dealership my dad works at.
Stainless steel nuts and washers. I did not remove the bolts that were embedded, but did replace any hardware with stainless steel. Available at most local hardware stores. Bring a nut with you to the store to compare sizes. The nut size on my OEM catalytic was 13mm socket, thread 8mm-1.25. Note that the spring kit comes with two bolts, both size 14mm. I spent $4.52 at the local Menards.
2000F-rated Rustoleum Primer & 2000F-rated Rustoleum Flat Black Paint. I bought mine through Home Depot. Most local stores will have this, although it may only be rated to 1200F. My 260K mile, 13 year old catalytic was working fine, but rusted out. To prevent this, I followed what Ecky did with his catalytics: rust-proofing them with heat and rust resistant paint. I did 2 coats of primer and 3 coats of paint, and then followed the instructions on the back of the can to cure it. The instructions are as follows:
- Bake at 250F for 30 minutes.
- Cool for 30 minutes.
- Bake at 450F for 30 minutes.
- Cool for 30 minutes.
- Bake at 600F for 30 minutes.
- Cool for 30 minutes.
Only difference is that I went more like ~25 minutes each and 550F for the last step since the oven couldn't go higher than 550.

Installation was fairly simple; the only mildly challenging part was compressing the springs from underneath while threading on the nuts to connect the two catalytic converter pipes. O2 sensors were reused.

Including tax and shipping total cost was less than $300. Considering the price of a replacement OEM catalytic converter alone is over $1300 on HondaPartsNow.com, I consider myself blessed.

Getting the catalytic converter off was another story though, took about an hour, but that was last Sunday. Had to take a torch to the O2 sensors to loosen them up, and I spent Saturday spraying the bolts down with Pb blaster to loosen them up every hour, which helped.

The Insight is now back to sounding as quiet as--or maybe even quieter than--it was back when I bought the car.

Picture of the catalytic after baking:

Pictures after installation:

And yes, I did reinstall my underbody paneling after installing the catalytic. Also, a quick picture of the plug I used for the rear wiper (Amazon link here):

06-06-2019, 10:53 PM	#195 (permalink)
mpg_numbers_guy Master EcoModder Join Date: Feb 2018 Location: VA Posts: 1,372 Toby - '13 Toyota Prius C Team Toyota 90 day: 63.99 mpg (US) Daz - '15 Mazda 3 iTouring w/ Tech Package Team Mazda 90 day: 38.2 mpg (US) Thanks: 324 Thanked 483 Times in 368 Posts	Thanks! I'll keep that in mind when working on the sound system some more. Just finished installing the new catalytic converter. CEL codes are all gone except for the hybrid battery one from the dirty bypass I have right now (switch off, BCM unplugged). Here are the parts I ordered for reference: Davico Catalytic Converter 58214 {#18194}. Aftermarket catalytic converter that is a direct fit to the Insight and is used by several other Insight owners. Available through Amazon, Ebay, and elsewhere. RockAuto has the lowest price of the three at $208.79. Link here. This catalytic also comes with Honda part #18229-S3Y-J01, which is the exhaust flange gasket to connect the two catalytic converter pipes. Dorman Pipe to Converter Spring Kit 03416. Also available through Amazon, Ebay, and any Honda parts store. RockAuto had the cheapest price at $3.31 each. 2 are needed. Link here. Exhaust Manifold Gasket. Honda Part # 18115-PHM-004. This may or may not have been able to be reused, but I went with a new part since I was removing it anyway to install the new catalytic. Price was only $4.22 through the Honda dealership my dad works at. Prices online vary from $4-$10. HondaPartsNow.com and Amazon are two online places that come to mind. RockAuto is/was out of stock at the time of writing this. Exhaust Manifold Stay. Honda Part # 11941-PHM-000. This is a support bracket that bolts onto the catalytic piping and onto the transmission housing. I replaced mine because it was rusted out. Deleting the support braket will likely make your catalytic conveter break apart at the welds after a while. Price was around $13 through the Honda dealership my dad works at. Stainless steel nuts and washers. I did not remove the bolts that were embedded, but did replace any hardware with stainless steel. Available at most local hardware stores. Bring a nut with you to the store to compare sizes. The nut size on my OEM catalytic was 13mm socket, thread 8mm-1.25. Note that the spring kit comes with two bolts, both size 14mm. I spent $4.52 at the local Menards. 2000F-rated Rustoleum Primer & 2000F-rated Rustoleum Flat Black Paint. I bought mine through Home Depot. Most local stores will have this, although it may only be rated to 1200F. My 260K mile, 13 year old catalytic was working fine, but rusted out. To prevent this, I followed what Ecky did with his catalytics: rust-proofing them with heat and rust resistant paint. I did 2 coats of primer and 3 coats of paint, and then followed the instructions on the back of the can to cure it. The instructions are as follows: Bake at 250F for 30 minutes. Cool for 30 minutes. Bake at 450F for 30 minutes. Cool for 30 minutes. Bake at 600F for 30 minutes. Cool for 30 minutes. Only difference is that I went more like ~25 minutes each and 550F for the last step since the oven couldn't go higher than 550. Installation was fairly simple; the only mildly challenging part was compressing the springs from underneath while threading on the nuts to connect the two catalytic converter pipes. O2 sensors were reused. Including tax and shipping total cost was less than $300. Considering the price of a replacement OEM catalytic converter alone is over $1300 on HondaPartsNow.com, I consider myself blessed. Getting the catalytic converter off was another story though, took about an hour, but that was last Sunday. Had to take a torch to the O2 sensors to loosen them up, and I spent Saturday spraying the bolts down with Pb blaster to loosen them up every hour, which helped. The Insight is now back to sounding as quiet as--or maybe even quieter than--it was back when I bought the car. Picture of the catalytic after baking: Pictures after installation: And yes, I did reinstall my underbody paneling after installing the catalytic. Also, a quick picture of the plug I used for the rear wiper (Amazon link here): Attached Thumbnails __________________ 2013 Toyota Prius C 2 (my car) 2015 Mazda 3 iTouring Hatchback w/ Tech Package (wife's car) Last edited by mpg_numbers_guy; 06-07-2019 at 10:14 PM..