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Discussion Starter #1
Hey guys! So I got a 2bular header kit https://www.2bular.co.uk/evora-s/engine-protection-kit installed on my 2013 Lotus Evora S IPS as well as the upgraded BOE intake. Everything fit in nicely and the sound is incredible, when the car stays on. It keeps shutting off and giving lean codes. Anyone have any idea what the problem could be?
 

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You have a few options, most of them involve leaks. Since you did a header and an intake at the same time, might be tricky to figure out where.

I'm not familiar with how many O2 sensors and banks we have in these cars, but if you are seeing a lean condition on a single bank, I'd guess you might have a leak on the headers on that side. If you're seeing a lean condition on both, you might have a leak on the intake or a problem with the MAF.

But basically, lean means the car thinks it's getting more air than it wants and has measured. If you have leaks at/after the MAF but before the O2 sensors, you will often see that condition as unmetered air enters.
 

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I recently tracked down an intake leak on mine with a smoke tester. If you plan on doing it yourself, I'd recommend using vegetable glycerin instead of mineral oil, as the latter smells horrible when heated/vaporized.
 

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I'm not familiar with how many O2 sensors and banks we have in these cars
2 banks of 3 (Bank 1 is closest to the trunk, and Bank 2 is closest to the "firewall"/mid-window), with a total of 4 O2 sensors. 2 of those sensors are pre-cats, and the other 2 are post-cats. All are before the 3rd cat, which is why removing it causes no CELs.
 

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2 banks of 3 (Bank 1 is closest to the trunk, and Bank 2 is closest to the "firewall"/mid-window), with a total of 4 O2 sensors. 2 of those sensors are pre-cats, and the other 2 are post-cats. All are before the 3rd cat, which is why removing it causes no CELs.
Makes sense, for a lean condition I would only expect it to apply to the pre-cat in any scenario. For post-cat you should throw cat efficiency instead. So if it's a single bank lean code you probably want to check the seal on the exhaust header for that bank. Wasn't sure if we had a 6->2->1 scenario with the pre-cat O2 sensor being after the merge to 1.
 

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Discussion Starter #6
Thanks guys! I will get back to you after they check for leaks!
 

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Illegal Alien
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2 banks of 3 (Bank 1 is closest to the trunk, and Bank 2 is closest to the "firewall"/mid-window), with a total of 4 O2 sensors. 2 of those sensors are pre-cats, and the other 2 are post-cats. All are before the 3rd cat, which is why removing it causes no CELs.
With Headers installed the original main cats are gone and the O2 sensors are positioned a) upstream individually in each header or downpipes (depending on manufacturer) and b) downstream of the "3rd Cat" next to each other.
 

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Illegal Alien
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Hey guys! So I got a 2bular header kit https://www.2bular.co.uk/evora-s/engine-protection-kit installed on my 2013 Lotus Evora S IPS as well as the upgraded BOE intake. Everything fit in nicely and the sound is incredible, when the car stays on. It keeps shutting off and giving lean codes. Anyone have any idea what the problem could be?
Which specific codes are given? I had 2 header types on my first Evora and never had a CEL in 5 yrs, the other day I had same type headers installed on my 410 and am seeing a code P0141 which is an O2 heater error, Lotus Service Notes say issue is a bad connection or bad wiring. The is a Bank 1 -Post Cat O2 sensor which uses an extension cable so most probably in the connector, I will track it down however this CEL does not limit engine performance so no rush to pull apart.
 

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I have the same full 2bular header-downpipe-metallic cat system, along with the BOE CAI, and never had and CEL's or codes.
As mentioned above, you probably have a leak somewhere.
Julian is correct; with the header system, your primary O2 sensors are moved from the headers down onto the downpipes, and the secondary O2 sensors are at the back of the Metallic cat, NOT in the downpipes as stock.
 

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Discussion Starter #10
Thanks guys for all of your input! I mentioned your ideas to my mechanic and he confirmed there are no leaks. I mentioned that because the new headers are going into the stock muffler that perhaps his weld there is leaking but also confirmed no leaks. Due to the lean condition he changed out the plugs since he stated that it was fouled up and now the car is not misfiring or throwing any lean codes, so far. It's not scheduled to goto the dyno for tuning! I will follow up once I get the results back!
 
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