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Old 08-23-2013, 05:19 AM   #1
mattwithcats
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Join Date: May 2011
Location: Portsmouth, Virginia
Posts: 1,365

2002 SL2
Default cat's (and exhaust pipe) hairball...

A lot of S-series owners have replaced catalytic converters and/ or exhaust pipes.
Trying to make a list of what works and what does not....

Please post info if you've made repairs to your exhaust...

Year / Model (02 SL2 for example)
Build Date (02/02)
Parts Replaced (five basic parts, manifold pipe with flex, cat, muffler pipe (may have resonator), muffler (mailbox or pumpkin), and tailpipe)
Reason (emissions, rust, broke, stupidity)
Does your car have a diverter valve?
Make and part numbers used...
Quality of parts?

This should help narrow down what cats work in passing emissions, and what parts are working well...

...
2002 Silver SL2, manual, 5th gear swap (.605), 78,000 miles, black badges,
205/60R15 "H" rated tires, 5mm spacers rear...
Pennzoil Ultra Platinum 5W-30, NAPA 41516...
NGK BKR6E-11 spark plugs

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Old 08-23-2013, 08:06 AM   #2
madpogue
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Location: Madison, WI USA
Posts: 25,713
 

1996 SW2
Default Re: cat's (and exhaust pipe) hairball...

'96 SW2, built 03/96 IIRC. No AIR pump, no pre-cat.

Cat "assembly" (downpipe+flexpipe+cat), along with rear O2 sensor, summer 2006, 95,00-ish miles
Performance drop, plus P0137 indicating failure of cat and/or rear sensor, and existing sensor would NOT come out of the cat (rust-welded)
Catco brand via Internet, rear O2 from dealer (BO&S), don't remember the numbers. Flange gaskets from FLAPS (forget the brand). Manifold flange lined up perfectly. Cat flange was "loose", so could be clocked to any position.
Cat-to-exhaust-pipe bolts/nuts were the worst to remove; much sawing, cursing, etc. Replaced with stainless. Manifold-downpipe nuts went smooth.
Clamp that holds the downpipe to the "bracket" on the bottom of the engine block broke. Replaced with simple u-bolt clamp, cut off ends for ground clearance.

Muffler strap, way back (2002-ish), rusted, dealer part.
Muffler (mailbox) failed (rust) the next year), rusted, replaced with Walker "stainless". Fabbed the strap to fit the smaller size. Tailpipe is part of the muffler.
Muffler again in 2006-ish. Unbolting the strap for installation of hitch, strap twisted and punched hole in the muffler. Replaced on warranty no questions asked.

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Old 08-23-2013, 10:17 AM   #3
TXSaturn02
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Location: Houston
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2002 SL2
Default Re: cat's (and exhaust pipe) hairball...

2002 SL2 (182,700ish miles) built in 8/2011

The exhaust system is all original and in good condition - some corrosion.

The diverter valve, dealer part (engine compartment - I assume there is only one) was replaced about a year ago at 177K miles, roughly, because of the infamous P0410 code.

...
2002 SL2 Manual - new in November, 2001
Sticker: $13,995 As of 09/30/17: 223,751 Miles - SOLD

2013 Mazda 3 HB - new in October 2012
Sticker: $20,850 As of 09/30/17: 38,381 Miles

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