Exhaust surprise!!

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
My 1998 Z3 1.9 has had an amazing exhaust rattle since purchase; not the silencer as I swapped that as one of the first attempted cures. It sailed through MOT with no problems a few days after I bought it six months ago. I reckoned it was the internals of the CAT - a US recall but not UK - and on removing the CAT section found a welded plate hidden on top as if someone had already tried a fix. The exhaust is dated 1997 so presumably original. My mate - he knows these things, so he tells me - told me to remove the CAT internals completely as since these engines are so good, my car would pass MOT with nothing there at all, but he took the exhaust away to fix it and after three weeks returned it. AND it still rattled, very loudly, on startup or any kind of acceleration. However having read the threads about the after-market Euro 2 CATS failing emissions I didn't want to risk one of those and as I couldn't find a second-hand version anywhere either locally or online had to buy new and direct from BMW. Yes, it cost me almost 40% of the price of the car and they declined to take the old one as a trade-in due to the welded plate.
However: the car is now transformed and the formerly lack-lustre acceleration in first and second is vastly improved. I was never impressed with the drive experience before but now it's a real ticket-gatherer.
I suspected this was down to a blockage in the CAT - my mate (he knows things!) was going to cut open the plate and sort out the CAT internals but instead spun me a yarn about putting a device down inside the exhaust that expanded and pushed the internal material out of the way thereby stopping the rattling and removing any obstruction. b*******s; I know he never looked at it. As I had no further use for the exhaust, I decided to open it up today.
IMG_7640.jpeg

Here's the patch on top, out of sight from beneath. Under that...
IMG_7641.jpeg

Here's another!! Amazing. So: cut that one out and...
IMG_7643.jpeg

Nothing. Completely empty CAT. No internals, no trace of ever having been any, and nothing to account for the rattle. Nothing to account for the poor performance either, no blockages anywhere.
So: will anyone care to debate as to why a car with NO CAT will pass emissions, when from when I've read on here the cheap sub-£200 Euro-2 CATs won't pass UK emissions, and how the performance was inhibited very badly with the straight-through exhaust fitted but a proper BMW CAT has now transformed it? I'm stumped, but happy. And poorer.
 

Zephyr

Zorg Guru (III)
Supporter
Joined
Aug 10, 2022
Points
136
If the lambda sensor is located after the missing cat, makes perfect sense.
The ecu had abnormal readings and tried to adjust to its emission settings.
so it never gave full power because emissions would be high.
 

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
Single sensor only, before the CAT. That's what makes it so strange to me.
 

Rudyrov

Zorg Guru (I)
American Zeds
Joined
Jan 29, 2014
Points
95
Location
Phoenix, AZ
Model of Z
2.8 L Roadster
Single sensor only, before the CAT. That's what makes it so strange to me.
I don't think the computer would sense that the cat was gutted if the Oxygen sensor is before the cat, it would just be a more free flowing exhaust, off course I am in the states and not UK so perhaps your computer is different?
I know we don't have the level of inspection that you have.
 

Zephyr

Zorg Guru (III)
Supporter
Joined
Aug 10, 2022
Points
136
But, if its a 98 M44 it should have two sensors according to the diagram.. puzled... so is it an m43?
diag_2qv1.png
 

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
It's an M44 according to the spec I checked using the VIN number, but both the old exhaust that I removed - marked 1997 - and the complete new unit from BMW only have one sensor, pre-cat. I could expect anything from 25 years of previous owners but not BMW themselves, who supplied the exhaust based on the VIN at the local Dealership. The date on the spec sheet is June 1998.
Both exhausts are identical bar the newer has only one 'dimple', the other on the old exhaust being where the resonation damper was fitted so I don't know where it goes on the new one.
IMG_7600.jpeg
 

Kiwipom

Dedicated Member
New Zealand Zeds
Joined
Apr 29, 2018
Points
43
Location
New Zealand
Model of Z
Z3 2.8 facelift
I don’t know about the z3 design of cat but on my ktm motorbike I took off the non cat mufflers and put back on the oem ones with cat, I could clearly see the cat section through the muffler end pipe, which is made up of very thin material in a sort of honey comb (actually more like that multi layer cardboard but in metal) ….it was pretty delicate and it would be easy to bang a hole through it for its (only) 100mm length. I guess this might be the case with this z3 cat.
In nz there are no checks on emissions so if you want more noise the cats are replaced with a straight pipe 😁
 

Zephyr

Zorg Guru (III)
Supporter
Joined
Aug 10, 2022
Points
136
First time I see the schematics to differ from the actual product.
maybe someone with an M44 can chime in and enlighten us.
 

Duncodin

Zorg Guru (III)
Supporter
Joined
Sep 8, 2021
Points
139
Location
Pontrhydyrun
Model of Z
Z3 M44
There's two exhausts in that picture. Won't there be visible connection holes/sockets in the pipe where sensors go?
 

Kiwipom

Dedicated Member
New Zealand Zeds
Joined
Apr 29, 2018
Points
43
Location
New Zealand
Model of Z
Z3 2.8 facelift
First time I see the schematics to differ from the actual product.
maybe someone with an M44 can chime in and enlighten us.
Its also a bit of an assumption that a post cat sensor is used for “adaptation“ (aka fine tuning) it may only be present to detect if the cat is stuffed or not?
 

Duncodin

Zorg Guru (III)
Supporter
Joined
Sep 8, 2021
Points
139
Location
Pontrhydyrun
Model of Z
Z3 M44
If I go to realoem and look up my car (M44) that second sensor is in the picture but it's greyed out so can't be selected.

But if I switch from EUR to USA spec that second sensor is not greyed out and can be selected.

So maybe something to do with regions and uk cars don't have that sensor?
 
Last edited:

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
There's two exhausts in that picture. Won't there be visible connection holes/sockets in the pipe where sensors go?
Old beside new, both identical bar the angle of the short post-CAT pipe. Only one screw-in socket along the entire length, pre-CAT.
Build date is January 22nd 1998, NOT June (that's the date of registration. ) Been in UK since new, one owner before me.
 

t-tony

Zorg Expert (II)
Supporter
British Zeds
#ZedShed
Joined
Dec 31, 2013
Points
226
Location
Torksey Lock,Lincoln, England
Model of Z
E89 Z4 23i Auto
Just in case anyone needs a plug to fill an O2 sensor hole, I have some.

Tony.
 

Zephyr

Zorg Guru (III)
Supporter
Joined
Aug 10, 2022
Points
136
Old beside new, both identical bar the angle of the short post-CAT pipe. Only one screw-in socket along the entire length, pre-CAT.
Build date is January 22nd 1998, NOT June (that's the date of registration. ) Been in UK since new, one owner before me.
diag_2qv1.png

January 98 UK spec has one. (and its called 1.8)
 

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
1897cc? According to my V5 anyway.
 

TriumphZ3

Dedicated Member
Joined
Aug 2, 2023
Points
39
That says M43 engine? If mine is claimed as M44, what's the visual difference so I can check?
 
Top