Rattlin' Cat

[Elanlover]

Sounds like it should be the name of a band............

Looks like the main cat has a bad rattle. When it was up on the hoist having the brakes done the mechanic was tapping and sure enough, it was the cat. Nothign seemed loose so I'm assuming the material is a lump in the housing and the cat will need replacing. So, I've got a few questions I'm hoping someone wiser than I can help with.

First, the mech tells me that the only way a cat will break (other than a direct, hard hit) is overheating. So, I'm worrried that something's going on in the engine I need to be concerned about. Now, its the original cat but the car's only got 4,000 original miles. I'm sure the engine's been run a lot more than that over the years with the car standing still though. I've got the v4.3 chip on the car and I run 94 Octane fuel which likely has a max of 10% ethanol in it (all we can get here if you want higher octane levels). I don't see the engine light on ever (except when starting of course). Could I have fried my cat with the chip or fuel or something else or is it possible that Old Man Time just caught up with it?

Secondly, the rest of the system look fine with little or not rust at all. So, I'm thinking of replacing the main cat with one that has a 2.25 diameter, having reducers on each end to mate to the original exhaust (if that can be done). This is all in the hopes that when i do replace the exhaust, i'll do it with a 2.25 system and salvage the cat if still good (which it should be as we're only talking a few years until I do the whole system anyway most likely). Anyone see any issues with this plan?

Many thanks as always!

[GeoffSmith]

Do you need a main cat? There are a few UK S2's (allegedly) that have lost the main cat, yet comfortably pass the emission test.

[Doug]

agree it sounds like the cat cells are loose -- I had this at 15K miles on stock Elan and it is not an uncommon problem.

Yes you either need a new cat, or like Geoff said you could remove it if not needed. You could likely just use a 2.25 inch cat and just have the ends of the 2" pipes flared a touch to fit it.

[Elanlover]

I'm going to need a main cat. the only reason is that there are laws here that prohibit shops from removing cats even if there is another one. Spoke to the guy at lunch who has suggested that i replace everything from the cat back with 2.25 gear and leave the precat and downpipe for later when I get a customer replacement made.

Wanted $900 CDN though Claims the muffler is the pricey part. Can't remember the name he quoted me but I'll look it up and post it here. I did see an example and you can look straight through it.

[Elanlover]

So Doug, you believe I shouldn't be too worried about the cat burning out? Was just very afraid the engine was spewing hotter than normal gas causing the cat to implode. Glad to hear the cat going isn't uncommon then...............

By the way, he wants to put a Remus muffler on it. Says they sound better, perform better, don't need a resonator and cost more I hear they are better known in Europe than over here. Can anyone share some feedback on Remus if they have any?

[GeoffSmith]

Blair,

A Peco is going to cost you less than $900CDN. Fit it yourself (just don't overtighten the clamps ) and job done.

Geoff

[Elanlover]

Thinking about that too Geoff, although I'd pay someone else to fit it I suppose. Still, with the exchange rate and shipping plus install I suspect it will come to $900 or more anyway. Will contact Peco too.

[Doug]

magnaflow or remus muffler is fine

yes, I just think it is a crappy cat design and the cell gets loose in there

could even go without a muffler if you have a cat in there and should be too loud (depends on how loud is too loud for you though)