Mini Mania, Inc. Service Bulletin

Subject: Catalytic Converter Considerations – NME1004, NME1104 & NME9004 units

Issue

While the off-road use type exhaust header & integral high flow catalytic converter provides excellent performance, some customers have experienced failure of the Catalytic Converter Element. Typical of this occurrence is for the EML light to trigger. Underlying OBD II codes may include P0108, P0420 and others, indicating low catalyst efficiency has been detected.Several failure modes are common to all catalytic converters in all applications. This document is intended to assist in the understanding catalytic converter failures and the underlying causes. 

Considerations

Lamba (O²) sensorAn O² sensor (lambda sensor) has an expected life span of about 30,000 to 50,000 miles. Sensors may fail prematurely if clogged with carbon, or contaminated by lead from leaded gas or silicone from an antifreeze leak or from silicone sealant used elswhere in the engine.O² sensors become sluggish as they age. Eventually the signal does not change at all. When this happens, the EML and/or check engine light may come on, and the engine may experience drivability problems or damage caused by an overly rich fuel condition. High fuel consumption, high CO and HC emissions, poor idle, and/or hesitation during acceleration are typical complaints.If the average voltage from the O² sensor is running high (more than 0.50V), it indicates a rich condition, possibly due to a bad MAP sensor, leaky injector or excessive fuel rail pressure. If the average voltage reading is running low (less than 0.45V), the mixture is running lean possibly due to a vacuum leak or because the sensor itself is bad.If the O² sensor continually reads high (rich), it will cause the engine computer to lean out the fuel mixture in an attempt to compensate for the rich reading. This can cause lean misfire, hesitation, stumbling, poor idle, high hydrocarbon emissions (from misfiring) and engine damage.

If the O² sensor continually reads low (lean), it will cause the engine computer to enrichen the fuel mixture. Injector pulse width will be increased causing fuel consumption and carbon monoxide emissions to go up. Especially in a performance tuned vehicle, a constantly rich fuel mixture can cause the catalytic converter to overheat and it may be melted.

 Converter Meltdown

In cases of an overheated Catalytic Converter the element deteriorates or melts, becomes dislodged and partially or fully plugs the exhaust outlet. Catalytic Meltdown occurs when the converter is super-heated due to a raw fuel condition in the exhaust flow. The excess unburned fuel ignites when it strikes the hot catalyst, burns inside the converter and drives the temperature far above the normal operating condition of the converter. The deteriorated element can then either break apart or dislodge completely and clog the exhaust system. This conditions results in poor performance high backpressure and correspondingly high compressor (supercharger) boost pressure. A converter glowing red hot or showing signs of heat discoloration are indicative of this condition.

Carbon DepositsCarbon deposits are an indication of too rich a mixture, or of oil or antifreeze entering the exhaust system. Heat backs up into the engine bay causing other heat related problems.

Catalyst Fracture

Ceramic catalytic elements can become loose, break down and deteriorate. This failure mode can be cause by road debris striking the casing, or by the packing material blowing out from around the element. Fracturing can also be caused when the element deteriorates due to overheating from raw fuel entering the exhaust system (see above).

Testing

Check OBD II codes periodically with an appropriate code reader (NME4020 or similar). Codes should be acted upon to preclude irreversible damage or a dangerous situation.

Note: A qualified technician observing proper safety procedures should perform testing.With the car safely on a lift, inspect the exhaust system and particularly the catalytic converter housing for evidence of damage by road debris.With the car still safely on a lift, separate the CAT back exhaust system from the header at the flange. With aid of a flashlight, perform a visual inspection to verify the catalytic element is intact and complete. Inspect for signs of catalytic converter overheating, such as a discolored housing. Reassemble if OK.Verify the proper operation of the upstream and downstream O² sensors.Using a 4 or 5 gas exhaust analyzer, verify that tailpipe emissions are within specifications.With ECU diagnostic equipment (such as the GT1) check fuel trims to verify proper ECU control of the engine operating parameters. The properly tuned engine will exhibit near neutral trims. Significant fuel trims should be addressed and corrected.An important step in diagnosing a the cause of a catastrophically failed catalytic converter is for a properly equipped shop to view your Mini Cooper’s long and short term “fuel trims”. Short term fuel trim is the real-time mechanism by which the fuel injection system is adjusted to provide the programmed performance and emissions. Long term fuel trims accumulate and are compiled within the ECU, and form a longer term moving average type database that follows the car’s overall fuel adjustment requirements. This reading is useful as a tell-tale to look at overall tuning of the vehicle.

An improper ECU map for the engine (due to inappropriate remapping, or the addition of performance parts without appropriate mapping), will cause long term fuel trim numbers more than a few percent.

Additional causes of converter meltdown damage include activation of the ECU's engine protection routine when the air intake charge becomes too hot. When the ECU detects that the air temperature in the intake manifold is too high, it causes the fuel injectors to deliver more gasoline than is needed in order to cool the intake charge. While the internal combustion components are cooled as intended, the excess fuel passes through the hot catalytic converter resulting in the possibility of converter meltdown as described above. This condition can be induced in tuned vehicles lacking improvements to the Intercooler. Superchargers run with inappropriately small supercharger pulleys (greater than 15% reduction) generates a great deal of excess heat, which must be dealt with via improved intercooling.

Remedy

Indications of a deposits or an overheated catalytic converter MUST be addressed before installing any replacement unit, or that unit may be damaged too.

1. Contact Mini Mania for price and availability of a header refurbished with a new high flow metallic catalytic converter (NME9004). These off road use only refurbished units require the return of a rebuildable core header.  

2.  Obtain a replacement catalytic converter independently and have a competent muffler shop replace the damaged catalytic converter by welding it in place of the original unit for your off-road use header. Be sure to check State and Federal regulations before proceeding.

3. Reinstall your original stock manifold with integral catalytic converter & reset computer.

4. Purchase a new replacement performance off-road header with catalytic converter.

Always reset the ECU when replacing the catalytic converter.

 Warranty Considerations:Warranty covers header materials and workmanship. Heat discoloration of the stainless steel tubing is considered normal (not a materials or workmanship related issue) and is not covered by warranty. Catalytic converters destroyed from overheating, deposits or impact damage, regardless of cause, are not eligible for warranty coverage.

Part No Applications: NME1004, NME1104, NME9004, NME6024, NME1105

Mini Mania
Article Date: May 18, 2005
Car Accociations: NEW_MINI
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Shipping Costs

Royal Mail (Recorded) – For UK customers only. This signed for service is for small items (e.g. keyrings, valve caps) under the value of £30.00. This service is NOT guaranteed next day delivery. Tracking numbers are available upon request. The price depends on the weight of the package, but is approximately £2.00 - £5.00

Parcel Force (UK) – For UK customers only. This method is for items over £30.00 in value. This is a signed for service and is guaranteed next day delivery (not including Saturdays). This is the most reliable UK service available. Tracking numbers are available upon request. The price for UK deliveries is £8.00.

Royal Mail International - Airmail (airsure) – This signed for service is for small items under the value of £30.00 only. Tracking numbers are available on request. The price depends upon the weight of the goods. You will be sent an e-mail with the delivery cost for your authorisation.

Available for the following countries: Andorra, Austria, Azores, Balearic Islands, Belgium, Canary Islands, Corsica, Denmark, Faroe Islands, Finland, France, Germany, Iceland, Liechtenstein, Luxembourg, Madeira, Monaco, Netherlands, New Zealand, Norway, Portugal, Republic of Ireland, Slovak Republic, Spain, Spitzbergen, Sweden, Switzerland and USA.

Parcel Force (International) – For items over £30.00 in value. This signed-for service is the most reliable for international deliveries. Depending on the destination country, they aim to deliver within 2-3 working days. The price depends upon the size and weight of the goods. You will be sent an e-mail with the delivery cost for your authorisation

Product Use Notice:

When ordering, recognize that some products sold by Mini Mania may not be approved for highway use on public roads. These products are designed for show, off road driving or racing applications only. It is the buyer’s responsibility to ensure that their vehicle meets all federal, state and local laws and regulations. Buyer assumes all liability and risk associated with the use of high performance products and holds Mini Mania, Inc. harmless of any associated liability.

Important Note:

Products distributed by Mini Mania, but manufactured by others, are subject to their respective manufacturer's warranty. Contact that manufacture directly for warranty support. If results are less than satisfactory, we want to know! Contact us and we will be pleased to intervene on your behalf.

Maximum Performance with Mini-mum Stress
Warranty backed performance

Mini Mania™ Limited Warranty The Mini Mania limited warranty is in effect for at least the remaining portion of your original
new car limited warranty, often longer since it extends also for one year or 12,000 miles after you purchase the Mini Mania part or component. This means more miles, more coverage, more assurance that your MINI stays at peak performance miles beyond anyone else in the industry. Mini Mania stands behind its warranty. We have been in business since 1974. Mini Mania's customer service extends beyond the sale of the product. Our product warranty offers our customers the peace of mind that only product warranties can offer. Our intent is to back our products in a manner that protects you against product defects and damage caused
by failure of a Mini Mania component. The Mini Mania warranty is intended to cover Mini Mania and/or ULTRIK manufactured products when they are used in the manner for which they were originally designed. Most Mini Mania parts and components will not impact your new car warranty. The warranty does not cover products subjected to improper installation, modification, misuse or customer neglect.

For MINIs covered under the Original Manufacturer's New Car Limited Warranty

If your MINI is currently covered by the new car limited warranty issued when the car was originally purchased,
Mini Mania will warranty its Mini Mania and/or ULTRIK branded performance upgrades for the remaining term of the new car limited warranty up to 4 years or 50,000 miles, whichever occurs first. Mini Mania warranties are transferable to subsequent owners of the car providing that the car falls within the original manufacturer's new car limited warranty criteria. To obtain service under the warranty, the vehicle must be transported to an authorized Mini Mania dealership or
MINI dealership who will obtain authorization from Mini Mania to make the requested repairs. The facility will, with-
out charge to the customer, either repair or replace the defective Mini Mania and/or ULTRIK branded part and/or the original vehicle manufacturer's part at the sole discretion of Mini Mania if it is determined that the Mini Mania and/or ULTRIK branded part caused the failure of the original vehicle manufacturer's part. Parts replaced by Mini Mania become the property of Mini Mania and/or the original vehicle manufacturer. In all cases, customers understand that a reasonable time period must be allowed to initiate and make warranted repairs to the vehicle.

For MINIs no longer covered by the Original Manufacturer's New Car Warranty

The Mini Mania limited warranty covers Mini Mania and/or ULTRIK branded products for two years, or 24,000 miles, from the date of the purchase, whichever is greater. Mini Mania's limited warranty is transferable to subsequent owners providing proof of original purchase can be presented. Mini Mania does not cover products subjected to improper installation, modification, misuse or customer neglect. In the event of a warranted claim, Mini Mania will, at its sole discretion, either replace or repair the failed component upon receipt of the Mini Mania and/or ULTRIK branded part. Labor charges associated with repair or replacement of a Mini Mania component will be reimbursed at the Mini Mania authorized standard rate based upon Mini Mania's schedule of flat rate labor costs. Mini Mania will not be responsible for consequential effects or damage to other components or systems. The defective Mini Mania part must be presented to Mini Mania or Mini Mania representative to verify defect and authorize repair or replacement.

Mini Mania's Limited Warranty Exclusions:

• Any vehicle operated in any competitive event; • brake rotor warp; • custom-designed competition parts; • damage attributable to negligence, improper installation, improper treatment or treatment contrary to the instructions in the owner's manual from the original vehicle manufacturer or Mini Mania's product instructions; • damage due to the failure to perform maintenance services at the specified intervals or in accordance with the instructions in the owner's manual from the original vehicle manufacturer or Mini Mania's product instructions; • damage occurring through corrosion resulting from weak or improper coolant; • damage resulting from environmental influences, flood, accident, fire damage, or road salt corrosion; • damage resulting from the unauthorized modification of a Mini Mania part or assembly; • damage resulting from the use of improper or contaminated fuel; • damage resulting from the use of other manufacturer's products in conjunction with Mini Mania products or systems; • damage to a component or assembly due to the installation of replacement parts with specifications that differ in any material respect from the original vehicle manufacturer's or Mini Mania parts; • damage to a Mini Mania component as a result of a collision or improper collision damage repairs; • damage to the clutch due to power shifting or abuse; • drive-belts; • engine damage resulting from altered boost pressure beyond that provided by Mini Mania products; • friction materials; • incidental and/or consequential damages, including loss of time, inconvenience or loss of the use of the vehicle; • light bulbs;
• maintenance services and parts when replaced during maintenance such as spark plugs, lubricants, fluids, engine tune-up parts, replacement of filters, coolant and refrigerant; • mechanical adjustments or repairs which result from normal wear and tear; • towing charges; • return shipping charges. This warranty shall be null and void if the vehicle identification number has been altered or cannot be read; if the odometer has been replaced or altered and the true mileage cannot be determined; if the vehicle has been declared a total loss or sold for salvage purposes; or if the vehicle has been used in any competitive event.

General

The duration of any implied warranties, including the implied warranty of merchantability, is limited to the duration of the express warranties herein. Mini Mania, Inc. hereby excludes incidental and consequential damages, including loss of time, inconvenience, or loss of the use of the vehicle, for any breach of any express or implied warranty, including the implied warranty of merchantability, applicable to the product. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitations and exclusions may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty applies to all Mini Mania and/or ULTRIK branded products purchased on or after July 1, 2004. Mini Mania, Inc. reserves the right to modify this warranty at its discretion and without notice. Mini Mania™ and the Mini Mania logo are trademarks of Mini Mania, Inc. ULTRIK and the ULTRIK logo are pending trademarks of Mini Mania, Inc.

Rev. 20041028A  

Our Guarantee:
Mini Mania will match the published price of any supplier in the USA! If you find an item advertised at a lower price from another US supplier, call us! We'll TRY to match that supplier's price -- see details below.

Quality, Service & Price
Mini Mania, Inc. has been supplying parts and accessories Mini owners for over 30 years and we are proud to continue to offer you the best guarantee in the market. QualityProducts sold or designed by Mini Mania are chosen for the quality of performance, looks and price. If for ANY reason you are not 100% satisfied we gladly accept the product back within 15 days of purchase for a full refund. Please see our full Return Policy below for details. ServiceOur 12,000 sq ft warehouse, a staff of 25 experts in their field, 12,000 parts number kept on hand, and $1,000,000 worth of inventory assures you of the utmost in service.


Prices & Price Matching
We offer the best product at the best price available on every item in our store. All prices are listed in U.S. dollars. We do not have a currency converter in our store, but several Web sites provide this service. Orders placed at minimania.com will be charged in U.S. dollars. If you live outside the U.S., this charge is converted by your bank into your local currency and should appear on your credit card statement in that currency.

We will match the published price of any US supplier* -- even their current sales prices! If you find an item advertised at a lower price, make a notation in your online order, call or email us your price match request (see terms and details below). We'll sell you the SAME item at the SAME price! If you've already purchased the item from us, we'll even price match (for store credit only) as long as you contact us with your request within 10 days of placing your order.

This offer is restricted to identical items offered for sale in writing or on the web. When making your price match request, you must provide us with a link to the competitor's Internet URL for the item, a copy of the written ad or written quotation, which must include suppliers part number, description and price.

Price Match Terms and Fine Print

We may choose not to price match in some cases; here are some reasons why:

• The competitor's product is not an exact match (identical manufacturer & model) with ours.
• The competitor with the lower price does not have the item in stock at their warehouse.
• The competitor's total price (including shipping, handling, rebates, taxes, etc.) is higher.
• The competitor's product is used, refurbished, reconditioned, or a display model.
• The competitor is not selling in US dollars.
• The product is a clearance or closeout item.
• The item is not found within the first 10 items listed on major search engine results.
• The competitor is not manufacturer authorized or has advertised below the manufacturers minimum allowed price for the item.

* Qualified U.S. Suppliers are established businesses that routinely and regularly sell the item to be matched from an established physical storefront or warehouse.

While we endeavor to maintain the accuracy of item availability, descriptions and availability, we reserve the right to correct errors. We reserve the right to choose not to honor this offer.

How to Request a Price Match

Place an order on-line and leave a comment at checkout. Provide the competitor's name, part number, item description, URL link to the exact item and the competitor's price anlong with your request to price match. If we agree to match the price, your order will be processed at that adjusted price. In the event we cannot match the price, we will notify you by email. We will hold you order for 3 business days.

Alternately, you may call us with your request. We'd love to talk with you. We will generally respond to price match requests within one business day.

SHIPMENT PROBLEMS?

Product shipped by Mini Mania is properly packaged and protected; therefore, damage in transit is the responsibility of the carrier. If a package appears damaged when you receive it, indicate the condition of the package on your receipt from the carrier. If damage is discovered upon opening the package, notify the carrier and Mini Mania immediately. Damage claims are handled through the carrier. Be sure to retain packing materials for carrier inspection.

Claims for missing items or error in shipment must be reported within 5 days of order receipt .

BACKORDERS

We endeavor to stock most of the items we sell. For Classic Minis, parts are frequently in limited supply and are difficult to keep on hand. the automatic shipment notification email you receive will identify backordered items and indicate the approximate date we expect to receive the item at our warehouse.

Shipment of items backordered is dependent upon our obtaining them from our various suppliers, many of which are overseas. Consolidated air freight shipments are made to us bi-monthly from the UK, which means obtaining the parts you order may take up to two shipment cycles (4-6 weeks). After 60 days has elapsed we may notify you that an item cannot be obtained and has been removed from your order. Please contact us if you would like us to re-order, as some items can become available again later.

Be sure to contact us if you wish to cancel your backorder to avoid unnecessary shipping and restocking charges once the item(s) you’ve ordered is shipped.

SPECIAL ORDERS

Some items are made available on a Special Order basis. These are typically items with very low demand that we choose not to keep in inventory, or items that are custom built or built to order. These items are ordered from their suppliers solely to fulfill your order. As such, these items require a 100% non-refundable deposit at the time the order is placed (power-unit orders require a $1,000 deposit before work begins). Because of the nature of Special Order items, your order cannot be cancelled once your order is accepted and deposit taken, nor can returns be accepted once the item has shipped.

Mini Mania Product Return Policy

PRODUCT RETURNSWe at Mini Mania value your satisfaction. We back up every sale with our Satisfaction Guarantee: If you're not fully satisfied with our products or service, we'll refund the purchase price.Please follow the instructions below carefully to ensure your return is accepted and processed promptly:1. Returned items must be in original condition, in original packaging, unused, uninstalled, unmarked and re-salable, with all documentation and packaging intact to be eligible for refund or credit.Electrical Components, VHS Tapes, DVDs, Software or Software Devices, Books and Special Order or Custom Built Items are not accepted for return.2. Call Mini Mania right away for a Return Authorization Number (RA#), with invoice in hand. Mini Mania will refuse unauthorized returns. If possible, speak with the Sales Tech who took your original order. A return authorization number will be provided for eligible returns.3. Include a copy of the original invoice in the box, including the completed return form included with the shipment. Write the RA# on the return form, and on the shipping label. Do not include the name of the Sales Tech who provided the RA# unless instructed to do so, or return processing may be unnecessarily delayed.4. Mini Mania must receive returned items within 15 days of your original receipt of the product to be eligible for a full refund. Items received between 15 and 45 days from date of receipt, or received without a copy of an Invoice, Return form and RA# are subject to a 15% re-stocking fee, and are eligible for store credit only. Returned items are subject to inspection prior to issuance of refund or credit. Credits or exchanges cannot be issued for used or incomplete returns. Items determined as ineligible for credit can be shipped back to the customer upon request, at customer’s expense. Unclaimed ineligible return items will be disposed of after 30 days.5. Send your package pre-paid, insured and traceable to: Mini Mania, Inc. Attn: Returns Dept. 870 Gold Flat Rd., Suite A Nevada City, CA 95959Package your return merchandise carefully. Credit will not be given for returned merchandise damage incurred in transit. No UPS Call Tags will be issued. With the exception of returns caused by our error, shipping costs for returned items are the buyer's sole responsibility. We do not accept returns shipped to us "COD Freight", nor do we pay outgoing freight charges.Please allow up to 3 weeks for your return to be processed and credit applied or refund issued. Credit may take up to 2 billing cycles to appear on your Credit Card statement.Refused shipments returned to Mini Mania do not automatically qualify for credit.

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On CLEARANCE: £199.00
List Price: £257.47
 
 

On SALE: £150.00
List Price: £235.00
 
 

On SALE: £8.50
List Price: £14.34