Need some help

[fixkick]

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.

sorry I was not more clear
sure you need a cat
but I was only telling you both cars 8valve, FED and CALIF left the factory new (CAMI) with the same 3way cat and same exact suzuki Part numbers. (16valve a different answer)
yes the EGR is dead lacking a cat
no holes at the CAT back pipes do not change fuel emission but it will suck in air and cause tail type smog station sniffer go nuts (huge oxygen readings)
the missing cat on any car has nasty fumes even in good tune, CO is high,  the cat is 3ways and 1 way is CO reduction and no cat you smell that nasty and very toxic CO gas.
carbon MONOXIDE, the silent killer.

do not run the car in any garage with persons in that garage. CO is deadly if allowed to accumulate. or worse if  rooms over garages.

sure aftermarket cat and exhuast is ok of calif visual inspections allow, it,  in calif there ar  4tests, 1 is visual 2nd is sniffer test. (and gas cap test)  and CEL out  hot engine test.

the cat missing only wrecks EGR.
the engine use the 02 sensor hot, to control fuel mix, at hot idle and steady cruise hot and never WOT. wide open throttle.
key factors of mixtures good
no bad spark, mag wires are best , and lost the longest and helps this weak park system run way better, NGK or BOSCH MAG wire or others.
fuel pressure at spec,
ECT not bad
IAT does little.
MAP is huge #1 player, at all times, and full time WOT> when 02 goes off line MAP runs the show for mix. (no hose cracks to map)

seems you are doing real well.

the newer year, has deep well and uses a huge slit, rubber surround gasket 4mm, earlier are paper 1mm step
the 1992 changed on one VIN serial number ,   after they went 4mm later years were 4mm, even 1998.
my guess is yours will be the paper gasket type but some cars have engine swaps and get the 1995 manifold.
if you use paper with the 4mm deep  lip  the STAT floats and fails,