Blown cats at 101,000 miles...what to do?

[z-curtis-s4]

Good Morning Everyone,

I know there are many many threads unfortunately about our cars cats and having issues. One day last week I was driving my B8 S4 which is Stage 2 and has approx. 101,000 miles and my epc light then check engine light appeared along with a change in sound from my exhaust. Luckily my car was still drivable to make it to the shop where it is currently sitting and waiting for my next BIG DECISION. At the shop it was diagnosed that I have 1 blown cat currently and it is clogging up my exhaust from breaking apart... So my question is what do I do next? Yes I have researched and read many threads on here.... I do not want test pipes or a set up where my car can not pass emissions along with other issues so I am leaning to either sell the car or fix it. I currently have stock exhaust set up and I am Emmanuel Design Stage 2. I have read a few threads about the OEM replacement Magnaflow cats and was wondering if anyone could tell me if that is a reliable good set up matched with stock exhaust or I could choose the extremely expensive route of buy Audi OEM cats for approx. $2,000 each!!! If I want to remain stock like are there any other options besides the 2 I mentioned. Please help or if you are interested in maybe buying my car I live in Maryland near Bel Air and would be happy to show you my car or could send you pics. It is Deep Sea Blue and mint condition inside and out and garage kept just has blown cats currently :( I look forward to everyone thoughts and advice. Thanks so much and let the games begin:)

[z-curtis-s4]

Just to clarify that I'm leaning towards the OEM replacement Magnaflow cats connected to my stock exhaust. Does anyone on here have this current set up? How do you like them? Are they good in your opinion etc? And/or can anyone give an estimated guess on how long you think they will last given my car is Stage 2. I really don't want to sell my car and would love to keep it another 30-50,000 miles.

[S4Y_BYEEE]

Garage auto sports just finished testing on epa compliant catted test pipes that cost much less than oem, and should last longer.

Check ‘em out

https://garageautosports.com/product...42518154412231

Bill the owner is on here too.


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[z-curtis-s4]

Thanks for your comment. It looks like it could be a 3 to 5 week back log if I decided to order these cats. Does anyone have experience using this product?

[MSq5]

What emission testing do you have? We have no testing in my state. So, I went with Red Star test pipes with downstream bottle Magnaflow 200 cats. Not emission compliant. Cat mainly serve to take care of smell.

[z-curtis-s4]

I live in Md and have regular emission testing every two years. Luckily I just passed before all my cat issues. I am looking for a set up that will pass emissions with no dash lights coming on. I am hoping the OEM replacement Magnaflow cats will work with no issues and no dash lights coming on. Still hoping there is someone out there running this setup. Please let me know if you are..

[timmyzr1]

Get Gesi cats! 10x better than the stock one! Pricey tho!

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[RoofRails]

Get Gesi cats! 10x better than the stock one! Pricey tho!

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GESI cats are not better than the stock ones. If you have to have cats the OEM cats are 100% the best option. GESI cats lasted just under a year on my Q5. When a metal matrix cat fails it will telescope out and fold in on itself. The likelihood of engine damage due to the obstruction goes way up. Most of the time when the OEM cats do fail, they break up and blow out. Clogged ones are usually a result of being fouled from oil (bad pcv) or coolant (bad IC bricks).

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[Twi7ch]

I recently went test pipes due to a flange blowing on my OEM cats.

The solution that's working best for me is CTS spacers, CTS TP, CTS downpipes with flowmaster 2000125 (200 cell HFC) followed by a Borla Pro XS and then stock all the way back.

I'm planning on replacing the center resonator with two Vibrant Ultra Quiet 1140 resonators.

This seems to be the best solution for keeping the sound tame and also keeping the odour to a minimum.
I'm only stage 2 SP so it's not putting as much heat through the HFC in the downpipes.

You could do the same but with gutted cats and spacers to pass emissions (assuming no sniff test).

If you lookup mys4dotorg website he does almost an identical exhaust setup. It's where I got the idea from.

[timmyzr1]

I have becker test pipe to awe unresonated dp WITH 2 Gesi 400 cell hfc AND wrapped to a Borla xpipe to awe touring exhaust! No odor at all, no rasp whatsoever , almost zero drone and sound extremely good! Pricey tho!

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[Dippy]

What emission testing do you have? We have no testing in my state. So, I went with Red Star test pipes with downstream bottle Magnaflow 200 cats. Not emission compliant. Cat mainly serve to take care of smell.

I don't want to hijack this thread but this interests me. If one state has lower (or no) requirements than neighbouring states, what's the situation about crossing the state line? If you live in a state with high requirements but near the border of one with lower requirements can you just drive to the other state and get your car "certified" there and continue to drive a car in your home state that might not pass testing?

[A665]

If you live in a state with high requirements but near the border of one with lower requirements can you just drive to the other state and get your car "certified" there and continue to drive a car in your home state that might not pass testing?

No. You must have your car inspected in the jurisdiction (state or county) where the vehicle is registered.

[Slvrbul8]

I don't want to hijack this thread but this interests me. If one state has lower (or no) requirements than neighbouring states, what's the situation about crossing the state line? If you live in a state with high requirements but near the border of one with lower requirements can you just drive to the other state and get your car "certified" there and continue to drive a car in your home state that might not pass testing?

You have to pass inspection in the state the vehicle is registered and tagged.

[z-curtis-s4]

That's why I feel like I need to get OEM replacement cats or Audi OEM one's so it will pass inspection. One more comment I know many have said the OEM cats are trash but my last over 40,000 miles on Stage 2. I just want to replace my cats and still drive the car. No shop or no one seems to be able to give me an estimate or timeframe if I put the OEM Magnaflow cats or even OEM Audi cats how long the new one's would last??? I wish someone could at least give me an educated guess on the time frame. What does everyone think on here?

[sepheroth86]

Gut them, 02 spacer, add a cat downstream if you can't deal with the smell or noise.

This will allow you to pass the visual test and the obd test.

[z-curtis-s4]

Gut them, 02 spacer, add a cat downstream if you can't deal with the smell or noise.

This will allow you to pass the visual test and the obd test.

Do you know if there will there be any check engine lights with this setup?

[z-curtis-s4]

I just talked to a mechanic that said he put OEM replacement magnaflow cats on a 2.0T and there was a cel:( I don't want to spend all this money just to still have a CEL at the end that never goes off. Any one have any other suggestions...I might have to put my car up forsale as is with blown cats. Any takers?

[sepheroth86]

Do you know if there will there be any check engine lights with this setup?

Many people on here run secondary o2 spacers to eliminate the CEL.

[RoofRails]

I just talked to a mechanic that said he put OEM replacement magnaflow cats on a 2.0T and there was a cel:( I don't want to spend all this money just to still have a CEL at the end that never goes off. Any one have any other suggestions...I might have to put my car up forsale as is with blown cats. Any takers?

You would be better off listing it in the classifieds sections. There is even a regional classifieds to target an audience closer to where you live.

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[mahhdd]

I have more sympathy for you than RoofRails does, lol.

1) RoofRails is more researched than anyone else here.
2) Failed cats aren't worth selling your car over.
3) Going back to OEM cats is OK; but, Stage 2 and running OEM cats is risky due to heat. No one can give you a timeframe on this, because it's pretty much a bad idea. To give you an idea, OEM cats can fail on an untuned car. If you go with OEM cats, you're going to pay a pretty penny for the cats, pay the labor, still have the risk of a failure. If you go this route, I wouldn't go Stage 2.
4) You could do Test Pipes, then choose a tuner with a Test Pipe file to remove the CEL on the dash... But now you have the smell and the trumpet sound this motor makes on test pipes
5) You could do a custom exhaust setup with #4 that pushes cats downstream, rather than going with OEM Cats, Magnaflow or Redstar.... JHM has downpipes that relocate the cats downstream to protect them from the heat, and you can have them baffled to reduce the volume and rasp....

Most ideal solution for reliability: Test Pipes, then figure out whether or not you want to keep your cats... If you do, move them downstream.

Want to know the reason I'm still stage 1?

I'm still on OEM cats.


P.S. It's clear you've done next to no research on this topic... This post is as much as you're going to get from me on this topic. Gotta start doing your own research and using the search function. These are super elementary questions, and I only posted so you wouldn't make the mistake of selling your car for scrap for a very fixable reason.

[RPMtech147]

DPs(or gut)+ tune, in Minecraft, of course. I've never had luck spacers in late model stuff.

[Slvrbul8]

Have you considered an aftermarket replacement set: https://www.rockauto.com/en/catalog/...converter,5808

Maybe someone on here has tried them. You can get both side's for $500.

[Fresh.S4]

LOL

[SForePlayin']

Have you tried sourcing from a (local) junk/salvage yard? Might get you the extra mileage you're looking for and not break the bank.

would love to keep it another 30-50,000 miles.

[sepheroth86]

Have you tried sourcing from a (local) junk/salvage yard? Might get you the extra mileage you're looking for and not break the bank.

I believe that it is illegal for businesses to sell used catalytic converters in the USA.

[z-curtis-s4]

I've considered used OEM cats but am very hesitant to ever really know of the condition their in since they would be used. I am baffled that there is no real solution to my problem.... if I don't want any cel or light on my dash it seems to the only solution is to just do OEM AUDI cats again. So everyone else who has test pipes installed has a cel on their dash? I know people have mentioned using a second o2 sensor but that seems to work for some people and not for others. I would consider gutting my cats and paring it with my stock exhaust but I really don't want a cel on my dash because I will never really know is the cel on for my gutted cats or for something else. I'd never be able to tell. Any suggestions.

P.S. I love everyone saying I've done no research or use search button. My first sentence talks about how I have researched and looked at the many threads on here about our unfortunate cat issue.

[mahhdd]

I've considered used OEM cats but am very hesitant to ever really know of the condition their in since they would be used. I am baffled that there is no real solution to my problem.... if I don't want any cel or light on my dash it seems to the only solution is to just do OEM AUDI cats again.

Bro...

Just lol.

You HAVEN'T done researched if you're saying this right now...

[mahhdd]

I edited my first post. Go re-read it.

[z-curtis-s4]

Bro...

Just lol.

You HAVEN'T done researched if you're saying this right now...

The best part is everyone is saying do research for a solution. There seems to be no solution besides me switching tunes to get cel off and getting test pipes and having my car sound like trash and can't pass emissions. That's my main issue is that no one can seem to offer an easy solution that my car can get the work that it needs done and still pass emissions/inspection. It is not helpful to keep reading do research or search. I have and am still not sure what my next move is. This is why I am on Audizine.

[JRYtheS4]

The best part is everyone is saying do research for a solution. There seems to be no solution besides me switching tunes to get cel off and getting test pipes and having my car sound like trash and can't pass emissions. That's my main issue is that no one can seem to offer an easy solution that my car can get the work that it needs done and still pass emissions/inspection. It is not helpful to keep reading do research or search. I have and am still not sure what my next move is. This is why I am on Audizine.

There's several possible solutions in this thread. For whatever reason you seem to be ignoring the advice you're getting.

The unfortunate reality is that if you're trying to build a street car, you have to keep it street legal. Modified/missing cats and ECU tunes are not legal. So you either accept the risks associated with playing the game, or you fold and keep your car stock. You pay to play.

If you can't find the solution on this forum, chances are that there isn't a solution. Personally I am waiting on the GAS catted test pipes to be thoroughly tested by some lucky members, and then that's what will go into my car. The next best solution to me would be relocated cats and o2 spacers.

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[RoofRails]

The best part is everyone is saying do research for a solution. There seems to be no solution besides me switching tunes to get cel off and getting test pipes and having my car sound like trash and can't pass emissions. That's my main issue is that no one can seem to offer an easy solution that my car can get the work that it needs done and still pass emissions/inspection. It is not helpful to keep reading do research or search. I have and am still not sure what my next move is. This is why I am on Audizine.

This is why I half jokingly recommend you sell your vehicle. It's actually my honest opinion. There is plenty of good advice in this thread, and there has been a solution to blowing cats since, like the second week of 2009. These vehicles are by no means cheap to maintain, but the Audi community has some of the best people you will ever encounter when it comes to their willingness to help fellow owners. I was able to have several solutions lined up before I ever blew my cats because of the time people took to write up and comment on posts. I'm not sure what else you want to hear. Replace your cats or add test pipes with a test pile file and put spacers in it every 2 years to pass emissions. It's really as simple as that.

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[mahhdd]

There seems to be no solution besides me switching tunes to get cel off and getting test pipes and having my car sound like trash and can't pass emissions. That's my main issue is that no one can seem to offer an easy solution that my car can get the work that it needs done and still pass emissions/inspection. It is not helpful to keep reading do research or search. I have and am still not sure what my next move is. This is why I am on Audizine.

1) OEM Cats + risk of melting them again (esp on Stage 2)
2) GAS catted test pipes + there's still risk of melting them due to the location of the cat being where it is!
3) Red Star cats - You will have to do spacers for this and maybe change your tune
4) Gutted Cats or Test Pipes, then custom what's downstream, and run O2 spacers depending on your tuner. 034 doesn't recommend them. Result should be no CEL, and will be no CEL if you're on 034. Exhaust may sound like trash depending on what you do.
5) Gutted Cats or Test Pipes, then JHM catted (and maybe baffled if you want) downpipes, , and run O2 spacers depending on your tuner. 034 doesn't recommend them. Result should be no CEL, and will be no CEL if you're on 034. Exhaust also won't sound like trash.

What are you not understanding???

I think you should do option 6...
6) Sell your vehicle and drive a Prius

[sepheroth86]

I think you should do option 6...
6) Sell your vehicle and drive a Prius

Opening bid of $1,100 for broken S4.

[ccssid]

- - - Updated - - -

1) OEM Cats + risk of melting them again (esp on Stage 2)
2) GAS catted test pipes + there's still risk of melting them due to the location of the cat being where it is!
3) Red Star cats - You will have to do spacers for this and maybe change your tune
4) Gutted Cats or Test Pipes, then custom what's downstream, and run O2 spacers depending on your tuner. 034 doesn't recommend them. Result should be no CEL, and will be no CEL if you're on 034. Exhaust may sound like trash depending on what you do.
5) Gutted Cats or Test Pipes, then JHM catted (and maybe baffled if you want) downpipes, , and run O2 spacers depending on your tuner. 034 doesn't recommend them. Result should be no CEL, and will be no CEL if you're on 034. Exhaust also won't sound like trash.

What are you not understanding???

I think you should do option 6...
6) Sell your vehicle and drive a Prius

5a): GAS will sell you downpipes with gesi 300 cell HFC

https://garageautosports.com/product...37406134567111

[sepheroth86]

- - - Updated - - -



5a): GAS will sell you downpipes with gesi 300 cell HFC

https://garageautosports.com/product...37406134567111

User "famous" on here had cats in his midpipe ("downpipe") and one failed.

[Fresh.S4]

we've got 2 current threads going about exhaust/ CEL lol....

and just NOW someone finally mentioned about staying AWAY from catted pipes in the oem location. (AKA REDSTAR AND GAS) !!!!! DONT FKING DO IT!

literally your only options:
gut your cats and run spacers
gut your cats and change your tune to 034/ie. they can code out the CEL.

no matter what, the moment you remove oem cats, your car WILL sound like shit. at this point the best you can do is keep adding mufflers/ resonators until you are content with the noise.
if you dont want to gut your cats, then run test pipes + aftermarket cats like magnaflow 200cell (cheapest option) or gesi 300cell (most expensive). that will help bring the noise back down if you dont touch the rest of your exhaust.
now if you remove the oem catback as well, your gonna be fighting with noise to your liking.

[mahhdd]

and just NOW someone finally mentioned about staying AWAY from catted pipes in the oem location. (AKA REDSTAR AND GAS) !!!!! DONT FKING DO IT!

Post #20

[S4Y_BYEEE]

we've got 2 current threads going about exhaust/ CEL lol....

and just NOW someone finally mentioned about staying AWAY from catted pipes in the oem location. (AKA REDSTAR AND GAS) !!!!! DONT FKING DO IT!

literally your only options:
gut your cats and run spacers
gut your cats and change your tune to 034/ie. they can code out the CEL.

no matter what, the moment you remove oem cats, your car WILL sound like shit. at this point the best you can do is keep adding mufflers/ resonators until you are content with the noise.
if you dont want to gut your cats, then run test pipes + aftermarket cats like magnaflow 200cell (cheapest option) or gesi 300cell (most expensive). that will help bring the noise back down if you dont touch the rest of your exhaust.
now if you remove the oem catback as well, your gonna be fighting with noise to your liking.

He is so right. I literally have 5 mufflers on my test piped car hahaha. and cats in the downpipes sound like shit, ask me how I know.

[Fresh.S4]

Post #20

doesnt say anything about staying away from GAS/RSE catted pipes.

your post #32 is what i was responding to..

[Fresh.S4]

He is so right. I literally have 5 mufflers on my test piped car hahaha. and cats in the downpipes sound like shit, ask me how I know.

ive got magnaflow cats after my TPs followed by polo exhaust. my 2k-3krpm range sounds like shit, but everything else is golden!