First, hope this is the right forum for this, I searched around and didn't really find much on this.

I installed a MM header with a custom metal substrate hi-flo cat a while back. The car runs fine, mostly. I have cold start issues where it has to warm up else it'll die if I try to drive it too quickly, almost like it's flooded.

After the install I started an getting a error code basically saying that my rear sensor was malfunctioning (I think it was p0136), essentially due to the higher flow of exhaust it thought my cat was missing/gutted or something. I replaced the sensors, and still the error came back. I dug around online and found that this is a common issue, and often times, a spacer on the rear sensor can help alleviate the issue. So I got a 90deg. elbow spacer that moves the sensor out of the exhaust stream, something like this:

--------------------/ <<cat \-----
--------------------\______/------ <<exhaust flow
sensor> ----_|


Now I keep getting p2096 that the system is running too lean. I have noticed a bit of pinging at WOT and so I'm not driving him hard, at all, to keep from doing any damage to the engine.

There isn't enough clearance to do a straight spacer and keep it from hitting the heat shielding.

I'm looking for options here, as I can't seem to get the system to find a happy medium between too rich/high flow and too lean. I'm aware that I need to get him tuned, but until then, if I have to go the route of putting the stock header back on and selling the MM one, then so be it, but I'd prefer to keep the header on. What have others done in this situation? What options do I have?

Any input/advise is appreciated.

 

when you get it tuned you can ask them to remove the code....also alote of ppl get the code when they do a header install... i heard that ppl dont get the code with the rmw head... performance wise it doesnt do anything to your car.. i got the exact same codes as you..

 

Yeah, I know the codes don't affect performance, but wasn't entirely sure if a tune would resolve the issue (makes sense that it would since it changes the a/f mixture to work with the mods). I don't have the $$ for the RMW head, that's further down the line of mods that remain.

 

I installed a Mynes V2, one of the things they do is use the OEM cat. I have had not one code since install and performance does not seem to be affected at all using the OEM cat.

 

I may have to find a really good exhaust shop to do some more work on the header then. I had hoped to keep my stock one in-tact, so may have to check around to see if someone is selling their stock header to have the cat swapped. I'm already $400 into it though, so I have to ask myself if it's worth it to do more work on it, or spend the $$ on one that is known to not have any issues

 

JCWSLAYER, I can see why, the primary O2 bung on the Mynes header is actually extended to not throw a code, same a using a 02 defouler and the stock cat is being used still.

 

It works is the point, not one code or problem in over 8 months.

 

If I could get a spacer on the rear one without the sensor hitting the heat shielding, I'd be golden, but there's not enough room. Unless I have a new bung welded in like 15deg angled down, but I don't like the idea of that hanging below the car.

Worst case is having my stock cat welded on the header at this point, or seeing if a tune can resolve the issue.

 

I'm assuming your car is either an 05 or 06, the dme software in the 05 and 06 is more sensitive then 02-04. Also the mini madness header from my experience always throws a 2098 or 2096 on the 05-06 due to the sensitive emissions monitoring in those year cars. The faults are because the dme thinks there is a leak in the exhaust system behind the cat due to the fact that its too free flowing.

 

The dme in the 05 06 cars is alot more sensitive than the 02-04 cars with emissions regulating. Every 05 06 car that I have ever worked in with the MM header always throws a 2096 or 2098 fault. You can reset the dme adaptations and it will go away for a day our maybe 2 years. The best fix would be a custom tune.

 

bntmoore, yes, I have an 05 (8/04), so that would explain it. Interesting you only have this issue with the MM headers. I'm going in for emissions testing tomorrow, it should pass, then after that I may just hold out for either a tune, or a different header, or both (the tune is needed regardless).

 

The stock header gets less credit than it deserves, its a decent design, I'm not ditching mine til after I get a sprintex. Also sorry for the double post above, my first post didn't show up so I wrote another and then they both showed up......

 

It may be "decent", but it's still fairly restrictive. Even without a tune, I noticed a huge difference when putting the MM one on. I may save up for a Milltek header, I know people who run that with no issues at all.

 

While I have an '03 MCS, just wanted to confirm no codes being generated by the Milltek header,catback system I have installed.

 

Well, I didn't pass Oregon emissions due to my p2096, so the stock header has to go back on today so I can pass. Probably end up leaving it on until I can afford the Milltek setup.

 

Update: I'm so frustrated. I put the stock header back on, still had p2096 bank 2 lean condition. Tonight, put in a new rear o2 sensor, cleared the codes, STILL p2096. WTF??

I'm using a bluetooth OBDII scanner and an app on my phone. I can clear the code but as soon as I turn my car off and back on, the light/code comes back.

I don't know what else to check/try/test at this point.

Any ideas??

 

I believe the P2096 is a hard code so you'll have to pass 40 odd clean drive cycles for it to be cleared. Call MINI to confirm and it may be covered under emissions warranty...9 years or 12 years etc.

Jeremy

 

First off I'm sorry for the troubles your encountering. Ok so this is what I would advise you to do, go to a mini dealer and have them reset all your dme adaptations, right now your dme is throwing codes because its seeing the values change too drastically so it thinks you have an issue with your cat/o2 sensor. Once the values are reset it will go into a learning mode where it will take all the values as new inputs and wont compare them to where your system was but it will learn what is going on right then, it has some adaptability built in so as long as your not completely catless it can adapt to the changes, unfortunately for you the 05-06 cars dmes run a stricter emissions control system as I mentioned before. Try that, if you dont have dealer near you then you could try a battery reset as well. To perform a battery reset you will need to disconnect the battery completely, you can leave it in the car but both cables need to be off to perform it, so both terminals off you will need to connect both disconnected cables to eachother with a 5amp fuse between them to protect the modules, let it sit this way for atleast 15mins, I do it for 20mins to be safe, make sure the battery has no contact with the cables at all, I use a towel to cover it so it doesnt touch the cables. This should reset all the modules, sometimes it works, sometimes not.... Goodluck!

 

Yes it may be covered under the 10yr 100k emissions warranty but its probably not the header, its most likely the dme values being out if wack.

 

I was figuring that it was a hard code. I'll call the dealer, but depends on what they want to charge to clear the codes.

Are there any code reset tools you can buy that clear the DME codes? I'm also aware that performing regular drive cycles will clear it eventually as well, and I have until the end of the month before my tags expire. But I can easily try the fuse/battery reset trick this weekend too.

Thanks guys, you're amazing.

 

You will need bmw/mini software based tool to reset the dme adaptations, I have not seen any tool out there with that capability outside of dealer diag tools..

 

Ugh, called them. $60-120 based on either 1/2hr or hour timeframe, and I'd have to leave my car a half a day. All for something that takes what...5 minutes?

 

I believe Bytetronik FA can clear your adaptations even though you don't have FA. If someone near you has it they may help you out. There may be someone in Seattle area with it.

 

I live in Portland now, I'll ask on the Portland board if anyone has something like that. Thank you!

 

Did you try the battery reset yet?