(02-19-2020, 06:41 PM)Von Wrote: I have a 94 Suzuki Sidekick JLX 4x4 with a 1.6L 16v engine. The PO removed the catalytic converter for some reason and now is straight piped. I installed the Doug Thorley 4-2-1 header on the vehicle for it came with it when bought but was never installed. The header will not meet with the existing mid pipe and the flange is different. Before I cut and weld the proper flange to the mid pipe should I get a cat converter and install. I’ve heard the EGR needs the back pressure from the cat to function properly or it will throw a 51 code. Is this true for this model and if so should I put the cat back in? I have no emissions laws where I am from so this question is purely to make sure it is running properly.

Thank You

(02-19-2020, 09:04 PM)fixkick Wrote:

(02-19-2020, 06:41 PM)Von Wrote: I have a 94 Suzuki Sidekick JLX 4x4 with a 1.6L 16v engine. The PO removed the catalytic converter for some reason and now is straight piped. I installed the Doug Thorley 4-2-1 header on the vehicle for it came with it when bought but was never installed. The header will not meet with the existing mid pipe and the flange is different. Before I cut and weld the proper flange to the mid pipe should I get a cat converter and install. I’ve heard the EGR needs the back pressure from the cat to function properly or it will throw a 51 code. Is this true for this model and if so should I put the cat back in? I have no emissions laws where I am from so this question is purely to make sure it is running properly.

Thank You

yes, cat back pressure makes the EGR work. (modulate)G16 engines
but code 51 is USA cars, is yours USA?  many cars in canada (all really) have there own ECU. (market code 28 ECU = canada)
if you open the hood and look up , and under and you see the USA smog sticker there from Suzukik
in the center it tells you USA EPA regulations or California. like this.

https://fixkick.com/specs/Body-TAGS/html/image_8.html

if you see that word USA< that is  Code 51 ECU.. by law..
the other down side, of no CAT is this..
1: hot summer day and engine.
2: parked at  RED light, for 10 min and windows down,  or worse 2door car top down.
3: the stench of raw exhaust,  can be really bad. drifting from rear to front of car..

that is it on EGR,  EGR can be very hard to get working , due to carbon build up in all paths.

(02-20-2020, 02:09 AM)Von Wrote:

(02-19-2020, 09:04 PM)fixkick Wrote:

(02-19-2020, 06:41 PM)Von Wrote: I have a 94 Suzuki Sidekick JLX 4x4 with a 1.6L 16v engine. The PO removed the catalytic converter for some reason and now is straight piped. I installed the Doug Thorley 4-2-1 header on the vehicle for it came with it when bought but was never installed. The header will not meet with the existing mid pipe and the flange is different. Before I cut and weld the proper flange to the mid pipe should I get a cat converter and install. I’ve heard the EGR needs the back pressure from the cat to function properly or it will throw a 51 code. Is this true for this model and if so should I put the cat back in? I have no emissions laws where I am from so this question is purely to make sure it is running properly.

Thank You

yes, cat back pressure makes the EGR work. (modulate)G16 engines
but code 51 is USA cars, is yours USA?  many cars in canada (all really) have there own ECU. (market code 28 ECU = canada)
if you open the hood and look up , and under and you see the USA smog sticker there from Suzukik
in the center it tells you USA EPA regulations or California. like this.

https://fixkick.com/specs/Body-TAGS/html/image_8.html

if you see that word USA< that is  Code 51 ECU.. by law..
the other down side, of no CAT is this..
1: hot summer day and engine.
2: parked at  RED light, for 10 min and windows down,  or worse 2door car top down.
3: the stench of raw exhaust,  can be really bad. drifting from rear to front of car..

that is it on EGR,  EGR can be very hard to get working , due to carbon build up in all paths.

So I will be getting a Cat converter then and will have to check out my EGR for I’m almost certain it is clogged by PO not running a cat. EGRs are more expensive than I thought on these vehicles. Any helpful cleaning tips would be appreciated here. Also is it ok to install my cat right behind the Doug Thorley header or do I need some space pipe between the header and the cat? 

Thank you

(02-20-2020, 05:35 AM)fixkick Wrote:

(02-20-2020, 02:09 AM)Von Wrote:

(02-19-2020, 09:04 PM)fixkick Wrote:

(02-19-2020, 06:41 PM)Von Wrote: I have a 94 Suzuki Sidekick JLX 4x4 with a 1.6L 16v engine. The PO removed the catalytic converter for some reason and now is straight piped. I installed the Doug Thorley 4-2-1 header on the vehicle for it came with it when bought but was never installed. The header will not meet with the existing mid pipe and the flange is different. Before I cut and weld the proper flange to the mid pipe should I get a cat converter and install. I’ve heard the EGR needs the back pressure from the cat to function properly or it will throw a 51 code. Is this true for this model and if so should I put the cat back in? I have no emissions laws where I am from so this question is purely to make sure it is running properly.

Thank You

yes, cat back pressure makes the EGR work. (modulate)G16 engines
but code 51 is USA cars, is yours USA?  many cars in canada (all really) have there own ECU. (market code 28 ECU = canada)
if you open the hood and look up , and under and you see the USA smog sticker there from Suzukik
in the center it tells you USA EPA regulations or California. like this.

https://fixkick.com/specs/Body-TAGS/html/image_8.html

if you see that word USA< that is  Code 51 ECU.. by law..
the other down side, of no CAT is this..
1: hot summer day and engine.
2: parked at  RED light, for 10 min and windows down,  or worse 2door car top down.
3: the stench of raw exhaust,  can be really bad. drifting from rear to front of car..

that is it on EGR,  EGR can be very hard to get working , due to carbon build up in all paths.

So I will be getting a Cat converter then and will have to check out my EGR for I’m almost certain it is clogged by PO not running a cat. EGRs are more expensive than I thought on these vehicles. Any helpful cleaning tips would be appreciated here. Also is it ok to install my cat right behind the Doug Thorley header or do I need some space pipe between the header and the cat? 

Thank you

i cant see your header, but the right one has the #4 port EGR path, there.
the real head ache is the 4 injectors EGR in the quad port intake manifold, from H3LL.
ouch
i have no idea if other parts are missing for EGR< no photos posted.  but EGR main, EGR mod valve and EGR VSV top the list.  1994.

they also sell 94 sidekicks in the South pacific islands with no smog parts at all called JDM cars, new. then,.k
is your hood sticker missing or no funny blue aluminum placard  VIN plate just to right of  battery (facing it) or even more odd maple leaf VIn Plates in canada.
I see all this stuff in 1 second flat in person,  VIN plates missing parts,  all that.
ok what header model is it? #

(02-20-2020, 11:45 PM)Wi fixkick Wrote: SOME of those headers made by Doug thorley are not made now (too few cars on road running I guess)
do you have this slot?


this header  has the magic hidden EGR slot..(and matching new gasket for that , calif CARB certified,  DO YOU have the slot; SOME DO NOT.

THY-716Y-C (or  THY-716Y-SS)   the SS I think is still made, for sure sold.







as you can see this 16v engine had 2 kinds of header,short and long, (calf, and fed)
long tube headers started in CALIF 1992 and later all cards when long.
ending this mess (fails hard) (had after burner plates inside the melt and block exh, flow, yah super bad.. long header is best, and not use  below #1 part

next up CALImini. 

long ago  they made these too  and are very good.

look for the tube   #4 port, seen at rear, here os CALMINI header is EGR fitted. SK703Y-S

(03-01-2020, 09:30 AM)Von Wrote:

(02-20-2020, 11:45 PM)Wi fixkick Wrote: SOME of those headers made by Doug thorley are not made now (too few cars on road running I guess)
do you have this slot?


this header  has the magic hidden EGR slot..(and matching new gasket for that , calif CARB certified,  DO YOU have the slot; SOME DO NOT.

THY-716Y-C (or  THY-716Y-SS)   the SS I think is still made, for sure sold.







as you can see this 16v engine had 2 kinds of header,short and long, (calf, and fed)
long tube headers started in CALIF 1992 and later all cards when long.
ending this mess (fails hard) (had after burner plates inside the melt and block exh, flow, yah super bad.. long header is best, and not use  below #1 part

next up CALImini. 

long ago  they made these too  and are very good.

look for the tube   #4 port, seen at rear, here os CALMINI header is EGR fitted. SK703Y-S

My header does have that slot. Also to bring you up to speed where I am at with it now, I got the new cat. It is not melted and is installed properly now. PO removed. Prior to that I checked main cog for damage, replaced the pugs gapped .28 and wires installed properly, I replaced the timing belt but did not move the main and cam crank independently, I set valve lash to .06 but they were only off at .05 and or 0.07 so not much adjustment. The vehicle ran before but will Crank and not start now.

Assuming that all my work is correct could the new cat be the reason for it not starting. Before you answer a little back story. After vehicle would not start I started looking around the engine bay. I found the EGR disconnected from the block with all wires and hoses still connected. It seems that the PO removed the Cat and the EGR. Could the EGR being removed be the reason with the new cat that the vehicle won’t start?