This is old thread but most recent I could find on aftermarket cats. I got 420 code, the engine has 100k mi, and it burned oil so bad it was rebuilt (its 2011). It has had a leaking wastegate forever, and it began to run rich (smell gas in exhaust when it started and mpg went down 10-20%). This all is over the last 3yrs so it didn't suddenly happen. I went through all the obvious stuff first (diverter valve, N75, coils/plugs, new MAF, etc) and nothing really changed. I bought the clip to tighten the waste gate but you have to remove cat to get to it, finally got around to doing it. The wastegate was loose as hell, and the clip really tightened it up (fingers crossed) FWIW.
So with all that said burning excessive oil in the past and running rich now can damage the substrate in the cat, so I went ahead and bought the aftermarket cat from Rock Auto along with new O2 sensors (as they could be playing a role in all this) so I could just swap them out and be covered. I am pretty disappointed with the aftermarket cat. The stock cat looked pretty decent, no damage, no buildup, etc. I was on the fence with getting high flow cat, but decided against it because I've been down that road and I prefer clean air... that isn't a judgement, I think a high flow cat is probably reasonably clean with a good performance bump, but it just isn't where I want to increase my footprint at this point in my life. I assumed the aftermarket cat that only met Fed standards and isn't CARB legal would be slightly better than OEM flow wise, and still be an improvement over a damaged OEM cat emissions wise. I really doubt that now! I will try to upload photos to photo hosting site later, but the tubing is smaller, the volume of the cat is substantially smaller (with same cell density), and there is all kinds of stupid design flaws and shoddy craftsmanship. Square edges at transitions, deep ridges from tooling at bend points (think OEM turbo inlet hose), smaller diameter, and horrible sloppy welds that have poor penetration, spatter everywhere, the material is low grade steel, it just goes on and on. This thing will increase turbo lag big time with the restriction it has compared to OEM.
I decided to clean the OEM one I have by soaking it in hot water with degreaser, and am just going to reinstall it, and send the aftermarket cat back. If it doesn't work I will buy a used OEM one. It may not be as bad in function as I am making it out to be, but I am not going to spend $400 to find out. I would rather lose $60 in shipping both ways and perhaps if anyone else is thinking about it and cares at all about performance, my $.02 can save you the hassle. There is no free lunch. haha
Its just one more variable I don't want to add. I suspect the precat O2 was bogged from the oil or it was just its time, so it began to run rich, perhaps the open wastegate added to create rich conditions, either way I am putting the old cat back on with new O2 sensors, and my tighter wastegate linkage, and hope for the best.
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