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:scratchhead: That is actually my long term plan right now. But Eastern & Magnaflow cats keep listing all Lotus Esprits as 2" internal diameter when clearly that is not the case, at least not on my Stevens car. Even my EBPV is 3" internal diam. If the universal gets welded up in place of the original cat it's going to look ugly. I'm afraid my Garret T3 will never forgive me.
I did look into that as a way forward. Unfortunately techs out here have said it is now prohibited. CA cars are supposed to have the original OEM equipment or approved "aftermarket equipment" that have an "executive order" that effectively waives the OEM cat requirement. In fact you have to have a reason for working on your own car's emissions equip period. I already have a licensed tech's vehicle test report so I can begin repairs.
Looks like sleekgt has covered it but I just went through this exact thing and solved it with the Magnaflow universal with the correct CARB number. Had the welder make a matching length of pipe so the new cat could be swapped out for track use.
I am starting a new invasion of British cars in California. We will not be thrown north into Oregon, east into Arizona, or west into the sea (like historical WW II Dunkirk).
We shall defend our island, whatever the cost may be, we shall fight on the beaches, we shall fight on the landing grounds, we shall fight in the fields and in the streets, we shall fight in the hills; we shall never surrender.
Emission performance of the catalytic converter was based on durability bench-aging by Lotus Engineering, Inc. using ARB-modified RAT-A bench-aging cycle for 75 hours as specified in Appendix A to the "California Evaluation Procedures for New Aftermarket Catalytic Converters" (Converter Evaluation Procedures).
Emission performance of the catalytic converter was based on durability bench-aging by Lotus Engineering, Inc. using ARB-modified RAT-A bench-aging cycle for 75 hours as specified in Appendix A to the "California Evaluation Procedures for New Aftermarket Catalytic Converters" (Converter Evaluation Procedures).
Thanks for all of the information on the CARB compliant aftermarket cats. I'm still concerned about the mounting flange on the turbo side. The floating flange allows a perfect fit at the three studs protruding from the Garrett T3 turbo housing. If the shop is off on the bend the turbo mount will eventually suffer.
I did notice that Magnaflow show another cat PN that is 2.5" in diameter cat under the same EO.
It may be possible to fabricate a mount to put the cat in the loop. Since you *are* using the car for *cough* off-road use, the cat can be removed when you *cough* are on the track and using a straight pipe or your gutted cat.
Using the cat to pass smog should be straight forward. Note that if the engine has other issues that cause high HC/CO, no cat will be able to clean that up.
Those are all good and salient points. For now, I've bypassed the crankcase breather hose so the engine can breath air/fuel again. The turbo, spark plugs, air filter, and 02 sensor are all new. The TPS has been adjusted within range (.5 idle). The IAC counts down into the 30/40 range @ 960 RPM (at idle). No codes or intake leaks are apparent, T-stat opens ~82C. The car starts at the turn of the key every time.
Freescan log looks good at idle now. The fuel pressure regulator, fuel pump, and fuel filter will all need to be tested at speed when the car is on the road again. I have hope.
Thanks for this information. I'm still hoping that Tom can come through with an OEM set-up (I also just realized I didn't say thanks!) Big, big thank you Tom!
:bow:
Questions:
Do you have the same inside diameter exhaust?
Do you have any photos of the exhaust after the shop build?
Is the Magnaflow cat still mounted vertically?
Did you add any hangers/fasteners to take load off of the turbo housing?
I have been looking at the photos from your 1989 Lotus Esprit engine rebuild. I dare say there is no other make or model of car, with a four cylinder engine, that has had this much time and devotion put into it. I have eaten off of dirtier restaurant plates than your engine.
Question: Do you have the Shift-linkage improvement kit from PNM Engineering installed?
I used the PNM bearings in the translator and their version on the articulated joints that go back n the distal end of the shifter cables when I did the first series of projects on the car. A while later I had to replace the shifter cables and those came with new OEM Heim joints so those are what are on the car currently.
I'm heading to the shop tomorrow morning and I'll give you an update on whether or not we have a cat/down pipe assembly available.
Thanks for the update. There's no hurry as the car has sat for two years in the garage. I have a 'fix it' registration tag that's good until mid June.
I was reading up on your posts from last year concerning poly bushings and the use of Syl-glide as a poly bushing lube.
Do you have any updates about what to use?
I'm pretty sure my front bushings are 'knackered' by the way the car likes to follow the grooves in the pavement. But I'm also going to inspect the upper & lower U-joints for excessive play and check the steering rack as well.
Well, sorry to report that while we have two stock downpipe assemblies in the shop both cats have been gutted.
As far as bushings, I am a fan of the inexpensive Energy Suspension polybushings that I have used for years. They fit all the rear links, upper and lower, and they fit the leading strut of the front lower A-arm. I just use a little Sil-glide on them when installing.
On my first '88 Esprit Turbo and then later on the second '88 that I have now, I had to get a new cat to pass Californica's draconian smog test. Both times, an aftermarket cat from Magnaflow worked beautifully. Any reputable muffler shop should have or be able to get one for you and it comes with the necessary E.O. # on the side that you absolutely must have to pass the visual segment of the test.
On my Esprits, it made a noticeable difference, sniffer-wise...the difference between pass and fail on a healthy, well-tuned Esprit with no other changes, other than the cat change between tests. New Magnaflow vs. aging, two decade old, but fully intact and functioning factory cat. The Magnaflow convertor seems to flow really well too as you can see through it, as opposed to the factory convertor with the swiss cheese/mesh blocking it.
Surprisingly, my butt dyno didn't notice all that much of a difference between the Magnaflow cat and a gutted factory cat, not that such a thing could ever have happened here in California. The gutted cat was noticeably louder though at full throttle.
On my Corvette, also with Magnaflow cats, the smog tech doing the visual test got up from underneath the car and was so happy! I asked him why and he said that the installer welded them in with the numbers facing in a way so as to facilitate his viewing them. He said that since they were not original, he would not have been able to pass it without those numbers. Something to keep in mind!
The Magnaflow convertor seems to flow really well too as you can see through it, as opposed to the factory convertor with the swiss cheese/mesh blocking it.
Forgot to say that you are far better off with a brand new modern cat than a 27 year old factory cat anyway, especially since the CA sniffer test levels are so stringent. I've read that even with new cats, their efficiency drops off considerably as they age and time goes on.
I guess Magnaflow is the way to go. Just a quick note on 'Lotus repair shops'. I've been turned down by at least three due to 'liability issues' so far. Master Tech Automotive Experts was the latest to refuse.
Make an appointment with CA BAR smog referee once you get the Magnaflow installed (with the serial number visible as Turbo R mentioned) AND bring the hardcopy of the Magnaflow CARB EO #. That is the *only* way to get the visual smog check passed (you still have to pass the sniffer test).
My late 88 was smogged once, but the next year, the same shop, same technician refused to smog it because of a MIL (Malfunction Indicator Light) was missing from dashboard (according to California's updated smog book).
The Lotus factory manual clearly states MIL is 89 and up; 88 doesn't have a MIL. I tried 2 more shops and refused due to missing MIL - no shop wants to lose their license because they overrode an official California reference book in favor of the Lotus factory manual.
I had to go to a California Bureau of Automotive Repair (BAR) and get it straightened out. The full gory thread from 2014 is located here:
I agree with SLEEK GT, but wanted to add that in my case, I have never had to go to the CA smog referee. I just went straight to the smog test place (after driving the car a bunch and getting her nice and hot) and took the test. The visual test is first and if they notice anything out of the ordinary, then they will need E.O. #s for that part. If they don't notice then it won't matter. If they do notice that you have different or new cats or if you mention that you do, then they will need the E.O.# off it so that they can enter it into the system. Once they do that, it should satisfy the requirement for that segment in the test. They do this all the time.
However, if they can't see the E.O. number(s) or a red flag pops up because of something they don't like or there is some question of actually meeting the visual test's requirements, then you need to go see the referee. Once the smog tech raises the issue and puts what he saw into the system, then like SLEEK GT said, going to a referee with all your supporting paperwork for the E.O. # pertaining to that specific car application is the only way to get it to pass the visual segment of the exam.
I say do the test first and hopefully, you won't need the referee.
Are you reelin' in the years Stowin' away the time...
Thanks for all of your comments. My Lotus failed smog just hours of exiting this great big car hauler tractor-trailer truck from "Curves Ahead".
The second photo is a DeLorean on the way to a future new home..or is it a past one?!?
:wink2:
Correct me if I'm wrong, but I think you said in an earlier post that it had been sitting for a couple years?
Even with a healthy older Esprit or any older car for that matter, it is generally said by car friends and smog techs that for best results, you should drive the car (ideally on a fairly long trip in the area) prior to the test. For example, in my case, I often take a trip from SF to Santa Cruz and back...I've had real good luck that way, even after my different cars have sat for years.
Also, make sure that on the day of the test, you get it nice and hot before you pull into the test place. California's sniffer standards are ridiculously stringent nowadays...you need every advantage you can get before you take the test. Not sure if you did that this time, but it might have made the critical difference.
Not sure how active Club Lotus LA is nowadays, but see if you can hook up with some local Esprit enthusiasts in your area.
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