P2096 is being persistent. (Downstream O2 sensor)

[7milesout]

Had that been apart before?

[Cani Lupine]

Nope, the original cat has never been loosened or removed. Pretty sure at least one of the bolts will break, so I want to make sure to have the replacements on hand before I start, since I don't have a backup vehicle.

[7milesout]

I got a feeling that it is welded studs with removable nuts. But I haven't looked in detail. Course ... that would not be wise to do that far back up in the exhaust stream where the exhaust is mo' hottuh, and the heat cycles are mo' exaggerated. So maybe I'm wrong.

But if it is welded studs, you ain'ta gonna wanna break one, lube that sucka up.

[Cani Lupine]

I actually looked up the parts already, they're bolts and springs, and around $10 EACH through a dealer. Four bolts and four springs is $80 in hardware alone.

It's crazy how expensive some of the parts are on this cheap car.

[7milesout]

I'm guessing you could find the same hardware set-up on www.mcmaster.com

[Cani Lupine]

So, the gasket I need is on backorder and would have to be special ordered direct from Japan, and take up to three months to get here. Looks like I'm going to have to get creative, or actually take it to a muffler shop for some cutting and welding.

[7milesout]

So, the gasket I need is on backorder and would have to be special ordered direct from Japan...

There's gotta be a daggone small gasket readily available, that will fit in that joint.

[Cani Lupine]

Unfortunately it's an oddly sized gasket, and actually shares a part number for a Smart Fortwo.

I've considered going with the SuperCircuit headers to get rid of the two flexible flanges, but that apparently also causes the same code, according to another thread here, because it only picks up one cylinder with the upstream wideband sensor.

[klroger]

and there's smoke coming up from past the cat when the tailpipe is blocked.

So is the exhaust leak after the Converter & After the down stream cat monitor??? Sorry, I'm confused now...

[Cani Lupine]

The leak is at the rear converter flange just after the downstream O2 sensor.