Hello first of all, new to the forum and this is my first post. I posted this question in another forum and was hoping I would get more hits on this one. Anyhow, I hope someone on here can offer some advice or suggestions to my current issue. My wife has an 02 Mini Cooper S, that she has had since almost brand new (I think we bought it back in 03). Anyhow, we took it to get service yesterday because the exhaust was making a really loud sound. Turns out the catalytic converter is cracked in half (Not sure how that happened). Have any of you ran into this on this model car? I am wondering what is involved in fixing this. Lastly, how hard is this to fix? I have installed an exhaust on my sport bike, and I am curiouse if it is a similar process. I am sure it will be more difficult than the bike, but is this a job for a serious mechanic or can a do it your selfer complete it? Anyhow, please let me know Thanks.

Elliott
Austin, TX

 

I'm not positive but I believe that the warranty is longer on emissions equipment than the rest of the warranty by federal law. That might be covered under that particular warranty. Call your dealer for info.

 

Yeah I think it is only 80,000 or 5 year, and she is over by 900 miles. Sucks. She did call the dealer to see if they would still cover it or do something to help. We don't have a Mini dealership here in Austin, the closest one is in San Antonio. They did not call back today, so we will check with them tomorrow.

 

Actually, 80,000 miles or 8 years, (still doesn't help you at 80,900 though).

 

As I understand it the cat on a MINI is a part of the exhaust manifold. You have to replace the whole thing.

 

I found this on ebay, so it gave me hope that the whole exhaust would not need to be replaced. However, with the compact nature of the engine compartment, does not look like it would be easy to replace the headers and the cat. However, I could be wrong, any do this themselves?
(I hope I am not violating any rule by posting this link to the auction, if so, my apologies.)
http://cgi.ebay.com/ebaymotors/ws/eB...60508&viewitem=

 

That's a good price. My neighbor had the cats on his Mazda 6 replaced for the tune of $2K.

 

The repair shop here in Austin, is saying the OEM part for the catalytic converter is $1500, and the labor is $175. The one on Ebay is looking a lot better to me, but the mechanic is saying that aftermarket parts like this usually fail emission tests and don't last long. However, this one looks pretty good. They are also telling us that there are a bunch of belts and mounts that need to be replaced (Relaying info from my Wife as she has been in contact with them.) Total costs are looking at $3000, and the mechanic is even telling her to sell the car after it is fixed if she does not want to continue to pay the high costs of maint on this vehicle. So not sure if this guy is pulling our leg or not, this is the only place in Austin that works on Minis (At least that we know of).

 

The manifold and cat are one piece.

Your better off buying an aftermarket header setup with cat that is much less than an OEM part.Check out Helix Motorsports(in the vendor directory) they have an OBX header with high flow cat for around $600. Find another shop as well or tackle it yourself if you have any problems you can always seek help here on NAM or shoot me a PM.

 

Thanks for the info, I figured I would try the one I found on Ebay, the guy has pretty decent feedback and assured me that it should work fine. Total with 2nd day UPS shipping was $375, and I can return it if it does not fit. The shop is only charging $145 to install it, so I figure I let them go through the hassle. We also need to have the right motor mounts relaced, the tensioner pulley, one of the belts (She did not say, which), and the inner Ball joints. Looking at around $900 or so after all said and done, including the aftermarket catalytic converter. I hope we are not getting screwed. I would like to take it somewhere else, but we don't know of anyone else that works on Minis here.

 

Be advised that if the original cat died due to thermal stress, the new cat will not last very long! Be sure to find out if you have a overheating cat; otherwise whatever kiiled the first one if just waiting to feast on the new one.

 

Can you explain a little more? I am not sure if the first cat failed because of thermal stress, but if that is what the usual cause it for the cat to crack, then what causes the thermal stress? What should we ask the mechanic to check out to avoid this from happening again? Thanks

 

Yes, for example too much raw fuel can cause the cat to overheat. Check the scan data using an OBD scanner to make sure the engine fuel/air is not at the limits, also review the pre and post cat o2 sensors for evidence of proper fuel control. Hope this helps and good luck.

PS you can also use a non contact pyrometer to measure the temperature of the cat.