It appears my cat has an exhaust leak. I'm assuming the oil can looking thing that is right at the end of the header is the cat. I can feel the air coming out of it, and it's getting noisier. The air is shooting out towards the front of the car, and it looks like the lower front seam has come undone? I also assume this cannot be fixed with a new cat back exhaust?

What are my options to remedy this?
- Get it welded if possible?
- Replace header and cat? Aftermarket, or a new stock one?

Thanks for you help,
Skottoman

 

If you are in the USA and the car has less than the required "EPA pollution system guarentee" miles on it, the dealer is responsible for repairing it. I don't know the mileage now, for my 1998 car it was 50,000 miles. I think in California it is 90 or 100.

John

 

There are two can-looking things, a pre-cat and the main cat:



It doesn't really matter which one is leaking though, since the header/cats assembly is one piece and, as Jdewey pointed out, is warrantied under the EPA's mandated emissions warranty. Just make sure the problem isn't a leaking exhaust manifold gasket (by the head) or the gasket at the junction between the header and the cat-back exhaust.

 

Wow! Thanks for those replies. It's definately the cat. Part #1 in that photo. It seems to have come unsealed at the front bottom seam, or cracked or something there.

Can you explain more about this EPA thing? I have over 50k miles, so it's not covered under warranty. I live in California, so is there some law that makes the dealer fix things like this regardless of warranty?

Thanks again for your help.
Cheers,
Skottoman

 

I'll have to look to see what the emission warranty is on the MINI. For most vehicles, it is quite a bit longer than the normal bumper to bumper type warranty. More like a rust or corrosion type of warranty. See what the manual says about that.

 

I'm surprised. I pulled up the warranty info on the website, (don't have my MINI here today), and other than the 4yr/50k warranty, it only offers 12 years on rust and corrosion for the 04-current. No mention of emission warranty, never noticed that before. Oh well, would be a good time for a new header/cat combo I suppose.

 

Thanks! I dont' know where my manual is, so if someone could inform me of that warranty, I would appreciate it.
Cheers,
Skottoman

 

Ack! So there is no California mandated warranty that says MINI needs to fix a leaking Cat?

Sure a new header/exhaust combo would be nice, but $$$$....

Cheers,
Skottoman

 

Even though the car is not under warranty, I'd still ask the dealer about it. In some cases the emissions period is good for 100,000 miles/five years. No MINI is five years old yet, and a leaking cat is a pure manufacturing defect that should have never gone out the door.

 

Thanks, I have left a message with my local MINI service to call me back. I'll see what they say about it...
Cheers.
Skottoman

 

Federal Emissions Performance Warranty







California Emission Control System Limited Warranty.

 

Summary from California Air Resources Board: http://www.arb.ca.gov/regs/title13/2039.pdf

Defect Warranty: http://www.arb.ca.gov/regs/title13/2037.pdf

Performance Warranty: http://www.arb.ca.gov/regs/title13/2038.pdf

 

Seems that you're likely covered (unless you have more than 80K on the Odometer.)

On pages 35 - 40 of my Service and Warranty Information booklet (2003), the following components
are covered to 7 years or 70,000 miles (whichever comes first) by the California Emission Control System Limited Warranty:

Intake Manifold (S only)
Engine Control Module
Super Charger/Intercooler (S only)
Exhaust Manifold
Exhaust Manifold with Catalyst
Three Way Catalytic Converter
Transmission Control Module (MC only)

but not if caused by:
accident, flood, misuse, modification, alteration, tampering, disconnection,
improper or inadequate maintenance except if performed by and authorized MINI Dealer doing repair work, use of leaded fuel or fuel other than as
specified in the Owner's Manual, altered odometer, altered VIN, or
declared a total loss.

It also covers anything that caused it to fail an emissions test in the first
3 years or 50,000 miles (whichever comes first)

For the Federal Emission Performance Warranty,

These are covered for 8 years or 80,000 miles (whichever comes first) :

Catalytic Converter
Engine Control Module (including on-board diagnostic system)

and these are covered for 2 years or 24,000 miles:

Air induction system
fuel metering system
ignition system
PCV system
Fuel evaporative control system
Exhaust system
Engine emission control system sensors/devices
OBD
Related parts associated with the above systems