I am popping the error code that indicated bad catalytic converter. Need to get past this before my next emission in several months. If I purchase one of the manifold/catalytic converter assemblies, would I be able to install is the Mini was on jack stands? WOuld I have enough clearance to do the work? While I am down there, I should probably install a new muffler. Any recommendations on parts?

 

You can install a new exhaust manifold from the bottom. It's a tight fit but will go in.

 

You shouldn't have that much of a problem. Make sure you use plenty of penetrating oil prior to trying to removing the bolts. I did have to grind off a few bolts on the pipes, so it;s a good idea to have a grinder and extra bolts..
Once you have the manifold off, if your oil cooler/ oil filter housing is leaking, it's much easier to get to and replace the gaskets.

 

Thanks for the tips. I will probably order the parts I need and schedule a long weekend to get it done. From what I have read, getting the manifold off is relatively straight forward. I can cut the bolts off after the cat and drop the rest. MY '04 has a single ball mod done before I purchased i. Any recommendations on cat and muffler to buy? Not looking for anything special performance wise.

 

For another car, when I got tired of a converter knocking when cold and buzzing when hot I bought a couple of used manifolds with the converter as part of the manifold from a business that specialized in salvage parts. I gave the manifolds a good shaking to check for any thing loose and rotated them this way and that to ensure the converter "brick" was not coming apart. When I was satisfied the converters were at least not showing any signs of issues I then handled them with kid gloves until I could get the car in to a dealer and have the tech swap out the old converters and put in the "new" ones.

Ahhhh, peace and quiet. Oh, and no more P0430. It would show up once in a while as the converter that was making the noise had a loose "brick" that would move out of position just enough to affect the exhaust gas flow through the converter.

The used converters cost me around $495/each but factory new ones were more than twice that.

 

I had been eyeballing a Milltek for a while and the general consensus is that they're one of the top recommended exhausts (if not THE top). However, I came across an Invidia exhaust at a junkyard, cleaned it up and I like it a lot. If you're not concerned with performance it's a bit cheaper than the Milltek and gives close to the same HP gain. It was also a cinch to install.

 

Have you driven much with the Invidia installed, to be able to give an opinion?

Still waffling on Invidia vs Milltek, and waiting for a killer deal.

 

I've put probably 1,000 miles on it I including a long trip to another city about 4-hours away. At lower RPM's there's no drone and it sounds loud enough when I stomp on it (at least compared to the stock exhaust) but this is all from the cabin. I'm torn because on one end I wanted something loud but at the same time I don't want a fart can. It's also unrealistic of me to want it to sound like my neighbor's cammed 5.0.

I'm considering doing the headers next to see if it changes the tone.

TL;DR I wish it was louder but all in all I'm very satisfied with it.

 

Now that I am stuck at home and not driving, I am finally getting around to thinking about replacing the catalytic convertor. Should have started thinking about this a couple of weeks ago. I am not worried about grinding off the bolts on the exhaust but I am nervous about the bolts on the exhaust manifold. Hate to have them break then I am in a world of hurt. But I am at the point that I need to do something as I won't pass the inspection I have in July. Not afraid to get dirty but i broke a bolt holding the strut to the steering knuckle on my last major work on the Cooper. I spent a day trying to drill it out before going to the junk yard and picking up a replacement steering knuckle.

You mentioned Milltek or Invidia. How much did they cost? This is a 2004 Cooper S. Would prefer not to spend a fortune. I see a bunch on Ebay but had run into issues in the past with fit on these aftermarket parts. Not married to brand or performance. Given the age, I was thinking of replacing Cat and Pipe but maybe it make sense to have someone weld a new cat into place.

Appreciate any thoughts.
Ian.

 

A little pricey but I LOVE my Borla... The sound is perfection to my ears. Fit and finish was perfect.

robj

 

I'm with you....

+1

 

Looking at the Borla website, are you refering to the Catback system without a cat convertor. I actually need the cat convertor (at least that first). Would like recommendation on a replacement catalytic convertor (with manifold?) so I can pass my emissions test. Coop has 130k.

 

How come NO ONE EVER mentions pacesetter? I have pacesetter on my car and imo it's the best sounding mini I've heard in person . It doesn't drone even as loud as it is.. it's got a good deep tone and its gives good pops and bangs between shifts and when revved. The fit is perfect too. So far I'm the only one on here I see running pacesetter . it's very well priced too !!!!
it is alittle too loud on my setup for me but I dont have a cat converter which I think would quiet it down juuuuuuust enough to make it perfect.

 

Yes, I was referring to the Cat Back Borla. Mine had 165K when I got it and from the looks of the weld at the cat it appeared that had been replaced at some point. In view of that I've never looked into a converter so no help there, sorry.

I did end up getting the Borla "Aggressive" but was leaning toward their "Touring" for some time. On their website they have some good videos/sound recordings and when I heard the deep tone of the "Aggressive" I was sold. Some deep "pops" but nothing irritating and great tone, no drone at all.

Robj

 

I have the CatBack Borla Sport, (aggressive) which is not loud at all, it does growl. I've taken many long distance trips no droning at all. When my exhaust manifold broke in half, I just got one from a NAM user, I think I spend $150 for the whole unit, (manifold/Cat). I still have the 2 pieces of my broken unit in my garage, if you want to pay for shipping I'll send it to you and all you'll need to do is get it welded and add the O2 sensor, just let me know?

 

I appreciate the offer. I don't have the ability to weld so probably not the best option for me.

 

You could have a shop weld it or, you can send a request to the following link to see if they still have the Exhaust Manifold:
https://www.northamericanmotoring.co...-part-out.html

 

I saw you've put in a request in for the part you need did you text him?

PLEASE TEXT ME FOR FASTEST RESPONSE (661) 400-9498

 

No I didn't text him and just saw your message. Unfortunatley I ordered a replacement manifold and Cat yesterday. Once I get my coop up on jacks, I am assuming the cat and manifold will slip in from the top? (I stand corrected. The instuctions at Pelican Parts indicate it comes out the bottom. Any tips and doing the replacement?
Take Care all

 

The Stock unit which is one piece comes out from the bottom. I would get a set of Bolt Extractors, the manifold bolts heat up and round easily. I would also get at least 4 replacement bolts. Once you removed the exhaust manifold. the Oil Filter housing and Oil Cooler is extremely easy to get to and replace the gaskets and O-Rings...May the Force be with you...

 

My order was cancelled. Supposidly didn't fit. Just texted the number above. Appreciate all of the comments. I am not afraid to get dirty on this. Just nervous about the exhaust manifold bolts bolts snapping off. I sprayed them with a couple of days ago. Will do that several times before I get to try to take it off next weekend. Still need to find an other set of jack stands..

 

Didn't have any problems with the bolts breaking, just rounded heads, get the nut extractor. The 02 sensors may give you a problem, if the give you a problem just trace back the wires and unplug them. You can take them off later.
It's not a difficult job.and you should be able to use same gasket if you didn't get one.

 

Thanks for the comments. How high up do you think I need to get the car on the jack stands so I have enough room to get it out. I replaced the O2 sensors a few months ago when I started getting error codes so should be good there.

 

As high as you can lift it safely. Remove the 8 exhaust manifold bolts first..

 

Got a hold of him and this might work. Just wanted to confirm that the exhaust manifold and an 06 mini cooper S California would work on my 04 cooper S. Would think so but cant hurt to ask. Just noticed that you are in Cobb county as well. I forgot that we had talked a couple of years ago. I ended up having someone do the bushings for me on that occasion.
Take Care