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2002 Prius front exhaust assembly

Discussion in 'Generation 1 Prius Discussion' started by JamesPartridge, Jan 17, 2017.

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  1. JamesPartridge

    JamesPartridge Junior Member

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    I have a 2002 (first gen) Prius, which came with a long, one-piece front exhaust pipe assembly (part # 1741021261) consisting of two catalytic converters and a resonator. On my car, the second of the two cats is rotted out due to rust and leaking exhaust gas, although there is no code present. I would like to avoid buying the entire front assembly, which goes for $950, and would rather have a welding shop cut out the rotted cat and weld in an aftermarket cat. Does anyone know if it would be possible to do this? Would it cause a code? The problem is that the cat in question came with a special actuator mechanism and a hydrocarbon capture device, completely unique to this model, and I'm assuming it would be hard to find one of these used. Since the O2 sensor is forward of the cat in question, and the heat sensor on the second cat I'm assuming is only for operating the actuator, not for generating codes, I'm assuming that the only issue would be ensuring that there is sufficient back-pressure, i.e., that there needs to be a second cat, but not necessarily one with the hydrocarbon capture function. Thanks y'all!

    Art's Automotive website has an excellent article that inspired this idea. In that case, it was the forward of the two cats that needed to be cut out and replaced, which, fortunately for those guys, didn't require any special actuator or HC capture feature.
     
    #1 JamesPartridge, Jan 17, 2017
    Last edited: Jan 18, 2017
  2. vaughnstark777

    vaughnstark777 Member

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    Is it your desire to, do your part to keep the environment clean or save money? If it's the former it'll probably cost you that $950 unless you can purchase one used. If it's the latter and you have tools, DIY skills and have an eBay account it will be significantly cheaper.
     
    #2 vaughnstark777, Jan 17, 2017
  3. JamesPartridge

    JamesPartridge Junior Member

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    Surely removing the second cat with its hydrocarbon absorber component and installing a generic aftermarket cat would increase my environmental impact, but the question was more of a technical one as to whether it would interfere with the road-worthiness of my vehicle and cause a code.
     
    #3 JamesPartridge, Jan 17, 2017
  4. Brian in Tucson

    Brian in Tucson Active Member

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    Walker makes a replacement assembly, but it's not certified for NY or CA and they won't ship to either state. It's under $300, but you'd need to ship to another state (ie. Vermont or Ohio) and go pick it up.

    Alternately, the Pull a part here has two Gen 1, but I don't know if they recycle the cats. Shipping is possible (tho probably not cheap. If they have one (been meaning to go anyhow) do you want me to see if I can get the better of two?

    Later, follow up. I looked at the 03 at the JY, they had recycled the cats--no luck
     
    #4 Brian in Tucson, Jan 18, 2017
    Last edited: Jan 18, 2017
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  5. Brian in Tucson

    Brian in Tucson Active Member

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    I guess it's true about the environmental impact, but look at it this way, It's better to have something for a working cat than nothing at all. Seems to me if it doesn't set codes, you're pretty much golden.
     
    #5 Brian in Tucson, Jan 18, 2017
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  6. JamesPartridge

    JamesPartridge Junior Member

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    Thanks! How would I go about finding that part? I'm having trouble locating it on the Walker website.
     
    #6 JamesPartridge, Dec 21, 2018
  7. Brian in Tucson

    Brian in Tucson Active Member

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    BOSAL 0961650 Premium Load; DAVICO 58290 {#18270}; EASTERN CATALYTIC 40544 ECO II

    These are all listed on Rock Auto. I would suggest you discuss these with a muffler shop. In NY, you may not be able to have them installed because of emission regs. However a day trip to a neighboring state could get it done Call ahead and have your parts shipped to the shop.. Midas did mine in Tucson for a bit more than $100 labor in the past year or two.
     
    #7 Brian in Tucson, Dec 21, 2018
  8. dabard051

    dabard051 Tinkerer-in-Charge

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    <bump> to this thread.

    I find the trickiest bit about using an aftermarket cat converter is getting a nice airtight fit between the new cat and the old pipe which contains the HCAC and the rest of the exhaust system. I have found that liberal use of muffler sealer goop in that connection prior to the exhaust pipe clamp, and then a Permatex or TigerPatch strip carefully applied around the juncture keeps the pipes fairly well sealed. The problem is that this joint gets lots of mechanical action, between the engine motion and the rest of the exhaust system (which is why it's on rubber hangers) and that this area becomes prone to leaks in a few months.

    In the salt-using portions of the US, the HCAC assembly is also prone to developing leaks (all that welding gives lots of places for corrosive salt & dirt to accumulate) and so that portion of the system needs a good looking at to keep the Prius nice and quiet.

    Similarly for the rear connector between the exhaust assembly (Toyota Part #17410-21261) and the muffler assembly (17430-21160).
     
    #8 dabard051, Aug 27, 2020
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