(09-30-2021, 04:26 AM)fixkick Wrote: factoid
the susuki EPC (master parts catalog)
shows only 1 cat for 92-95, 8valve engine , not 2, and not cal fed , only 16v has that deal

61a02 then later 61a03 (03 code is 2004 year)
just looked it  up.
so there is no cal cat, (it is marketing abuse i guess)

(10-05-2021, 04:02 AM)sina27 Wrote:

(09-30-2021, 04:26 AM)fixkick 92 8v fed engine car. 2doors. VIN not told. Wrote: factoid
the susuki EPC (master parts catalog)
shows only 1 cat for 92-95, 8valve engine , not 2, and not cal fed , only 16v has that deal

61a02 then later 61a03 (03 code is 2004 year parts book not car year.)   BOTH CATS ARE THE SAme 8v.
just looked it  up.
so there is no cal cat, (it is marketing abuse i guess)

Thank You,

Even though the car is a FED car I will need to have a CAT installed for it to pass smog since I live in california. Dont these cars need a CAT for the proper back pressure to be applied in order to make the EGR system properly function? 
I actually noticed that there is a large hole in the pipe BEFORE the muffler, which is why the car may be idling so oddly (no back pressure) and is loud. Maybe this is what may be causing it to run rich and smell like gas?
I plan on taking my car to a muffler shop and have them put on a California compliant CAT, even if its a custom job.

I also ordered a new thermostat (BECK 1430688) (hopefully this is the correct one??) along with a couple different gasket types which I will determine which one to use when I pull the STAT. Do you know offhand which STAT gasket I should use?
well this year had 2 intake manifolds and  uses 2 radial different thermostats. 1mm rim and 4mm rim.



I ordered 3 different gaskets from rock auto: FelPro 35432, FelPro 36102, and FelPro 35416.
I can measure the thermostat lip to determine the correct one to use.....
In addition, I ordered a ECT sensor and a ECT sender / gauge from NAPA which I will also be installing when I put the new STAT in. \

On top of all this Im changing the front and rear diff oil with Sta Lube 80W 90 GL5, the transfer case with Sta Lube 85-90 Gl4, and the transmission with Penzoil Syncrhomesh.

(10-06-2021, 02:23 AM)sina27 1992-8v Wrote: Thanks !

Okay
SO - the BECK 1430688 thermostat I ordered will work for BOTH the 1mm and 4mm lip models, correct?
To determine which GASKET I use with this thermostat, I should measure the lip - if 4mm lip, I will use the rubber O-RING. If 1mm lip, I will use the paper gasket.
 (I ordered both gasket and o-ring from rock auto). 

So your explanation of why the CAT is necessary for the EGR to work properly might explain why the car idles rough. Hopefully the CAT installation will help this issue. 

Thanks for the help Kick!

(10-06-2021, 02:45 AM)fixkick Wrote: your engine may be paper only STAT , IDK,  only looking proves the pudding.
old cars can have wrong parts.  easy as eating cheery pie.
or swaps.  this old. 29 years old now.  not  some spring chicken , it is OLD OLD
so old now I see 1 per month on the road, rare,.

one trick is the drain out 1gallon  of coolant (1/2?)
off the stat lid and look , put back lid , put back saved coolant above, and be ready.
or as you said both gaskets in hand first. (me that is what I do)

(10-06-2021, 02:45 AM)fixkick Wrote: your engine may be paper only STAT , IDK,  only looking proves the pudding.
old cars can have wrong parts.  easy as eating cheery pie.
or swaps.  this old. 29 years old now.  not  some spring chicken , it is OLD OLD
so old now I see 1 per month on the road, rare,.

one trick is the drain out 1gallon  of coolant (1/2?)
off the stat lid and look , put back lid , put back saved coolant above, and be ready.
or as you said both gaskets in hand first. (me that is what I do)

(10-06-2021, 11:10 AM)sina27 Wrote: so i changd the rear and front axle oils. i also changed the transmission oil wiith penzoil synchromesh. 
i wanted to change the transfer case oil, but the top oil screw is stripped. i can open the bottom drain one if i want to. 
is there a way to add the correct amount of oil without removing the top oil screw? Maybe through the speedo / gear part that slips out from the t-case (the one with the 10mm bolt on back of transfer case). or by removing the rear slip yoke / seal and adding it through there? 
NO, we just use tig./mig welder and fast , weld on a bolt to the stripped hole, cured.



I forget if car hood says CALIF or not and if the ECU is CALIF or not.  both matter, for works right and smog man not angry.
about the high idle / surging: 
i have to replace the EGR valve because i broke one of the metal nipples thast connects to hosing.
Oreily has the california egr valve for my car -
i can install that one and make sure to install the thermoprobe -
the thermoprobe wiring just wouldnt connect to anyting, correct? 
the CAL EGR fit  any FED/cal car, only the wires are not used on FED. nor are there wires in the harness for  it  if Fed car, , fed harness, and fed ECU. 
The FED EGR  fails hard on any CALIF car (ECU tag number looks up as CALIF, Code 033 ecu , code 03 is FED. see? the ECU part number matters  most of all, then harness too.
what matters is what ECU p/n# is there

hopefully once i replace the ECT sensor/sender, the STAT, the EGR valve, and then get a CAT installed and fix the hole in the exhaust pipe, this willl all resolve the high idle and surging during warmup....
EGR will not cure surge,, only dead ECT in this will, nor new cat make engine run better  but egr + cat does stop pinging sure.

but you did just mention that a broken EGR valve or lack of back pressure wouldnt cause high idle or surging....so hopefully the issue is with the stat or ECT sensors....not sure what else it might be...the ISC is new.