Don't overspend when replacing the OEM catalytic converter! The ALTA Performance™ Cooper and Cooper S replacement catalytic converter with header is a great option for those needing to replace their non-functioning, or out of warranty converter. 

Our replacement catalytic converter includes the proper approval for use in all states that do not require CARB approval. We also include a 5 year / 50,000 mile warranty. This high-quality converter combined with our header make for a great alternative to spending too much for a new OEM part.

Our header portion of the catalytic converter replacement is a 4-to-1 design similar to the OEM header.  This allows for the OEM heat shield to be installed keeping the excess heat from entering the engine bay, and possibly your intake system. The header uses 1.5" tubing, and 11" long primaries, before making it to the collector. The rest of the piping is 2.5" to match your 2.5" exhaust system.

These features make the ALTA Performance™ catalyst replacement a legal option (see notes on catalyst replacement prior to ordering specific to your state, not legal for use or sale in California), a better looking option, and a less expensive option, for those in need of a replacement catalytic converter. Plus the performance gains that are realized when combined with the header and a proper catalyst are HUGE!

 

 

Design of Catalytic Converter

The ALTA Performance™ headers feature a four into one (4-1) design converging exhaust gases just before the metallic catalytic converter. The catalytic converter is a high quality 300 cell per inch, metallic core. A 5 year/50,000 mile warranty, which follows the needs of aftermarket replacement converters is included. The body of the cat is fully polished 304SS, with the EPA code left visible. This code is required for certification during emissions testing. The converter is designed to exceed the needs of the Mini Cooper 1.6L engine.
The ALTA Performance™ header can be a legal replacement in most states no requiring CARB approval. (Check local emission laws for restrictions in your area.)

The catalytic converter is manufactured using a unique spinning process. The metallic catalyst substrate is held in the middle, and the body is literally spun around it.  This provides a weld free, tightly held substrate that will never come loose!

The metallic substrate itself is a very important feature to not leave out. Most converters sold utilize a ceramic substrate. The ceramic substrate is constructed with much thicker walled cells compared to the metallic type. This added thickness creates friction, and in turn extra heat.  This causes the catalyst to run at very high temps, and can cause the converter to meltdown!  Our metallic catalyst runs cool and strong in any situation!

Proper placement of the converter is crucial for proper operation and legality. We place the converter in the same location as in the OEM header. This allows for proper clearance to the body and reduces backpressure from improper location.

Flex Joint

A small item that goes unnoticed is the flex joint. Because the MINI Cooper Runs such High EGT's (Exhaust Gas Temperature), the normal off the shelf flex joints simply can't cut it.  Our flex joint is a specially made joint that used 321 SS bellows (the part that flexes) and a special liner. The bellows are very thin corrugated stainless steel. The thickness, and the corrugation is what allow the part to flex. But because the bellows are so thin, they can be damaged with extreme heat.  This is where our liner comes into play. The liner provides a heat barrier between the super high EGT's and the thin bellows. This is what will keep our flex joint lasting for the life of your MINI!

Design of Header

The final critical portion of the ALTA Mini Catalyst Replacement is the header.  The headers go above and beyond the OEM 4-to-1 design. Constructed of 304 stainless steel, the 1.5" mandrel-bent primaries are made 11" long to provide smooth transitions from the exhaust ports to the collector. Our flanges are thick CNC machined 304ss flanges, not mild steel, or chrome plated steel flanges that will rust over time.  After the primaries collect, the mandrel bent 2.5" tubing connects the catalytic converter to our 2.5" outlet flange.  The ALTA Performance™ headers will fit nicely to either a stock or preferably an ALTA™ cat-back exhaust system.

All of these features make the ALTA Performance™ catalyst replacement w/header, stand out above all others!
 

 

• Header

CATALYTIC CONVERTER USE Q&A

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY WASHINGTON, D.C.   20460

WHAT YOU SHOULD KNOW ABOUT USING, INSTALLING, OR BUYING AFTERMARKET EQUIPTMENT CONTAINING CATALYTIC CONVERTERS.

Manufactures and retailers may not fully understand the intricacies of federal laws surrounding to replacement of catalytic converts and emissions equipment.  We have compiled answers to a few common questions in an effort to clarify the laws, which pertain to our consumers and the vehicles, which they drive.

 When can I install an aftermarket converter?

Generally, there are only 3 situations when you can install an aftermarket converter. They are:
1. If the converter is missing from the vehicle when brought in for exhaust system repair; or
2. If a State or local inspection program has determined the existing converter has been lead poisoned, damaged, or otherwise needs replacement; or
3. If the vehicle is more than 5 years old or has more than 50,000 miles* ( 8 years/80,000 miles for 1995 and newer vehicles ) and a legitimate need for replacement has been established and appropriately documented (e.g., a plugged converter or unrepairable exhaust leaks).

 What should customers know about buying converters for their cars?

First and most importantly, the original converter on a car or truck was designed to last the life of the vehicle if it is properly used and maintained, and is fully warranted by the vehicle manufacturer to last for at least 5 years or 50,000 miles (8 years or 80,000 miles on 1995 and newer cars and trucks ), whichever comes first.   See the vehicle warranty booklet for more information.

It is illegal to remove a functional catalytic converter even to replace it with a new one.

It is illegal to tamper with emission control devices. The Anti-tampering Law applies to individuals as well as to businesses.   Individuals may be fined as much as $2,500 for each vehicle tampered with, and businesses are subject to fines of up to $25,000.

How can I tell if an aftermarket converter meets EPA requirements?

Any converter, which meets EPA requirements and is an acceptable, legal, substitute must be properly labeled and warranted to meet Federal durability and performance standards.  

Manufacturers of new aftermarket converters are required to have a 5 year/50,000 mile warranty on the converter shell and end pipes.   They are also required to be warranted to meet EPA's emission performance standards for 25,000 miles when the vehicle is properly used and maintained. All manufacturers who meet the requirements also must state that fact in writing and obtain an individual manufacturers EPA code.   Usually this is stated in the warranty information or application catalog.

EPA requirements a new, legal replacement catalytic converter must be properly labeled.

Required labels on the converters will have a series of letters and numbers and be in the following format:
∑ N/XX/YYYY/ZZZZ
∑ N - indicates a new converter  
∑ XX - is the manufacturer's code issued by EPA     
∑ YYYY - is usually a numerical designation of the vehicle application or         part number       
∑ ZZZZ - is the month and year of manufacture (i.e., "0187" for January 1987)

Note: Converters manufactured for sale in California may have the letters "CA" in place of the "N" or "U".   Since California standards are more stringent than EPA's, these converters will also meet EPA requirements.  If your new catalytic converter does not have this label it may not be a legal replacement part for your application, placing you in violation of federal law.

What are the requirements for businesses installing an aftermarket converter?

Besides installing aftermarket converters only in the 3 situations outlined prior, other requirements and restrictions also apply.   These include completely documenting the need for converter replacement, properly installing the correct one on the vehicle, and informing the customer of his rights and certain restrictions. Specifically, these requirements are as follows:

•  If the replacement is not required by a State or local program, both customer and installer must sign a statement concerning why the converter was replaced. (Manufacturers either provide such a statement with the converter or have an example in their catalogs.)
•  If the replacement is required by a State or local program, the installer must keep a copy of the statement or order by the program representative.
•  The invoice for replacement must include the customer's name and complete address, and the vehicle's make, model year, and mileage, as well as the reason for replacement.
•  Retain copies of the above invoices and statements for 6 months and the replaced converters for 15 days (converters must be identified or marked as to which customer's car they came from).

•  Install the converter in the same location as the original.
•  Install the same type of converter as the original (oxidation, 3-way, or 3-way-plusoxidation (dual-bed)).   This information is sometimes available on the emission tuneup label or from the manufacturer's application catalog.
•  Install the proper converter for the vehicle as determined and specified by the converter manufacturer.   There are engine size and vehicle weight limitations which make it inappropriate to install certain converters on certain vehicles.   Newer vehicles with On-Board Diagnostic (OBD) systems may not always operate properly with certain aftermarket products.   Therefore, the catalog should always be consulted for the correct application.
•  The converter must always be properly connected to any existing air injection components.
•  Install all the other required converters the vehicle would have originally come with unless the converter manufacturer has stated in writing that the aftermarket converter is designed to replace more than one converter.
•  For new aftermarket converters, the installer must fill out the warranty information card supplied by the manufacturer and give it to the vehicle owner or operator.

What may happen if I don't use the correct converter?

It is a violation of Federal law because it is likely to increase the amount of pollution coming out of the vehicle.   Penalties for violations by individuals, service or repair shops or fleet operators are up to $2,500 per violation.   (Each improper installation is considered a violation.)   New car dealers can be penalized up to $25,000 per violation.   Any person who causes a violation could be subject to the same penalty as the installer. Vehicle performance can also be affected by the use of the wrong converter and, in some severe cases, converter or engine overheating could occur, resulting in unsafe operation and possibly engine damage.   The conditions or even simply the use of the wrong part on a vehicle may allow the converter manufacturer to not honor the 25,000 mile of the 5 year/50,000 mile warranty,

It is illegal to tamper with emission control devices. The Antitampering Law applies to individuals as well as to businesses.   Individuals may be fined as much as $2,500 for each vehicle tampered with, and businesses are subject to fines of up to $25,000.

Below is the graph of our catalyst replacement w/header on an 2006 Mini Cooper S with the stock intake, a 15% Supercharger pulley installed, and our 2.5" Catback exhaust. 

  Below is the graph of our catalyst replacement w/header on an 2006 Mini Cooper S with the ALTA cold air intake, a 15% Supercharger pulley installed, and our 2.5" Catback exhaust.

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