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Catalytic converter issues

Old 05-14-2019, 08:29 PM
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Catalytic converter issues

Last year my 2004 RX8 exhaust smelled very rich. I replaced the OEM exhaust with a TurboXS including the catalytic converter. Fast forward 8 months and the rich exhaust smell is back. I changed both O2 sensors. I get a P2096 post Cat fuel trim bank 1 fault (Too lean). In addition, idle surges. Anyone experience similar issues?Could the Cat be bad?
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Old 05-15-2019, 07:21 AM
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The TurboXS cat is crap. The rest of the pipe is good but the cat is just a spiral metal unit. Mine is throwing a P0420 code after less than a year.

That said, there's a HUGE list of possible causes for a P2096...
P2096 page from FSM

Factory Service Manual

Combined with idle surges, I'm putting my nickel down on vacuum leak.
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Old 05-17-2019, 08:16 AM
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The ONLY cats that can stand up to the heat produced by this engine are the factory cat, the cat BHR uses in their midpipes (street only), and some units from HJS (imported from Germany). That statement is true ONLY if you keep your ignition components healthy at all times. Failing ignition components cause fuel and oil to be dumped into the cat, which clogs it. The heat and backpressure from the clog kills the rear rotor in the engine.

This is why we stress the hell out of staying on top of your coils, wires, and plugs.

All the other aftermarket cats burn out due to the 1700F EGT produced by this engine under load. Most cats are rated for 1200F.
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Old 05-17-2019, 08:39 AM
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It should be noted that the HJS cats recommended by their own engineers for our cars are their 350PS/5L units.
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Old 05-18-2019, 01:39 AM
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Originally Posted by NotAPreppie View Post
It should be noted that the HJS cats recommended by their own engineers for our cars are their 350PS/5L units.
link?

beers
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Old 05-18-2019, 08:30 AM
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Sorry, not their engineers but one of their US reps.
Originally Posted by Steve Dallas View Post
The cat I bought was recommended to me by the rep at HJS NA, after I sent him a chart of my rear O2 sensor temps on track. He said it would stand up to that abuse, and is the same cat used by Porsche in the 911 Turbo as OE. Supposedly has 3 winding centers instead of 2, like their motorsports cats.
Originally Posted by Jastreb View Post
You can buy an HJS cat that meets Euro 5 specifications. AFAIK our cars only ever satisfied the Euro 4 spec. I believe Euro 5 has a lower limit for NOx.

HJS Hi-Flow 200 C.P.S.I. Universal Tuning Catalyst HD 9095 0182 - HJS North America, LLC : Hi-Flow Universal Catalytic Converters
Originally Posted by Steve Dallas View Post
^ That is the cat I had welded into my BHR midpipe. I have only had it for a couple of months, but so far, so good. No CELs and very little stench. I have 3 track days on it, and it it holding up fine for now.
That link is dead so here's an updated one to 90 95 0182

https://www.hjs-motorsport.de/produc...catalysts.html
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Old 05-18-2019, 04:36 PM
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Originally Posted by NotAPreppie View Post
Sorry, not their engineers but one of their US reps.






That link is dead so here's an updated one to 90 95 0182

https://www.hjs-motorsport.de/produc...catalysts.html
now how to get one in the states! lol

beers
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Old 05-18-2019, 11:05 PM
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You just import your oversized cocktail shaker from Germany like I did; twice.

Which mine is sitting in the garage now that I’m moving into a non-emissions race class ...

but this is the 100 cpi race version, never had a cel with it though, about 6” diameter on the main body, so not the small restrictive type that gets overhyped as high flow

HJS-Nr. 90 95 0050
GT 1407/10 PE3.1 kgup to 400 hp/up to 3000 ccm,

https://www.hjs-motorsport.de/produc...catalysts.html



Last edited by TeamRX8; 05-18-2019 at 11:16 PM.
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Old 05-19-2019, 12:11 AM
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Originally Posted by TeamRX8 View Post
You just import your oversized cocktail shaker from Germany like I did; twice.

Which mine is sitting in the garage now that I’m moving into a non-emissions race class ...

but this is the 100 cpi race version, never had a cel with it though, about 6” diameter on the main body, so not the small restrictive type that gets overhyped as high flow

HJS-Nr. 90 95 0050
GT 1407/10 PE3.1 kgup to 400 hp/up to 3000 ccm,

https://www.hjs-motorsport.de/produc...catalysts.html



sell it to me, or you will never see your compression tester again! lol.

funny, hjs had a corporate office about an hour from me for a few years. and now that i am back into the rx8 game not so much.

cocktail shaker indeed.

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Old 05-19-2019, 10:56 AM
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Thanks for the FSM, vacuum leak and Cat info. I'll let you know what I find.
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