1. Introduction
The Walker Standard EPA 15038 Universal Catalytic Converter is designed to reduce tailpipe emissions and meet EPA emissions requirements for pre-OBDII vehicles (1995 and older). This manual provides essential information for proper installation, operation, and general understanding of the product.
Image 1.1: A silver-colored universal catalytic converter with a ribbed body and inlet/outlet pipes on either end.
2. Compatibility
This universal catalytic converter is suitable for a range of pre-OBDII vehicles (1995 and older). It features a 2.5-inch (ID) inlet and a 2.5-inch (ID) outlet. Specific vehicle applications include, but are not limited to:
- 1986-1988 Porsche 944
- 1985 Volvo 745
- 1993-1995 Volvo 850
- 1986-1989 Peugeot 505
- 1987, 1992 Isuzu Impulse
- 1993-1995 Isuzu Rodeo
It is crucial to verify compatibility with your specific vehicle's year, make, model, engine, and trim before purchase and installation. Consult manufacturer guidelines or product fitment tools for accurate application details.
3. Features and Design
The Walker 15038 catalytic converter incorporates several design elements for performance and durability:
- Durable Construction: Features a stainless-steel body combined with aluminized pipe and heat shields for enhanced longevity.
- Flexible Solution: Designed for customizable installation, including expandable bushings for easier fitment. Installation may require specialized fabrication or welding.
- OE-Style Design: Includes aluminized heat shields, where originally equipped, to protect the vehicle's undercarriage from heat generated by the converter.
Image 3.1: Close-up view of metal exhaust pipe flanges, illustrating connection points for exhaust system components.
4. Installation (Setup)
Installation of the universal catalytic converter requires mechanical expertise and may involve fabrication and welding. It is recommended that installation be performed by a qualified technician.
- Preparation: Ensure the vehicle is safely lifted and secured. Allow the exhaust system to cool completely before beginning work.
- Removal of Old Converter: Carefully remove the existing catalytic converter and any associated exhaust components. Note the orientation and connection points.
- Fitment and Fabrication: Position the new Walker 15038 converter. Due to its universal design, custom pipe cutting, bending, and welding may be necessary to integrate it into the existing exhaust system. The 2.5-inch inlet and outlet are designed to slip over 2.5-inch OD pipes.
- Welding: Securely weld all connections to prevent exhaust leaks. Ensure proper alignment to avoid stress on the exhaust system.
- Inspection: After installation, inspect all welds and connections for leaks. Ensure adequate clearance from other vehicle components.
- No Break-In Required: The converter is ready for operation immediately after installation; no specific break-in period is necessary.
Image 4.1: A mechanic installing an exhaust system component under a vehicle.
Image 4.2: A close-up view of a person welding a metal exhaust component, with sparks visible.
5. Operation and Emissions Compliance
The Walker 15038 catalytic converter is designed to operate effectively in reducing harmful emissions from pre-OBDII vehicles. It is EPA compliant, meaning it meets the emissions standards set by the Environmental Protection Agency for use in all states except where stricter regulations (such as CARB compliance) apply.
For vehicles 1995 and older, this converter provides the necessary reduction in tailpipe emissions to help pass state and local emissions tests. Always consult your state's aftermarket converter regulations for specific details regarding compliance requirements.
Image 5.1: Logos indicating compliance with EPA (Environmental Protection Agency) and CARB (California Air Resources Board) emissions standards.
Image 5.2: A chart comparing different types of Walker catalytic converters based on installation requirements and regulatory compliance.
6. Maintenance
The Walker 15038 Universal Catalytic Converter is designed for long-term performance and typically requires no routine user maintenance. Regular vehicle maintenance, including proper engine tuning and timely oil changes, contributes to the optimal functioning and lifespan of the catalytic converter by preventing contaminants from reaching the catalyst.
7. Troubleshooting
If you experience issues after installing a new catalytic converter, such as a persistent Check Engine Light or failure to pass emissions tests, consider the following:
- Check Engine Light (P0420/P0430): These codes typically indicate catalytic converter inefficiency. While a new converter should resolve this, other factors like faulty oxygen sensors, exhaust leaks, or engine misfires can also trigger these codes. Ensure all related components are functioning correctly.
- Exhaust Leaks: Even small leaks in the exhaust system, especially upstream of the oxygen sensors or converter, can affect emissions readings and converter performance. Inspect all connections and welds.
- Engine Condition: A poorly running engine (e.g., burning oil, excessive fuel consumption, misfires) can damage a new catalytic converter over time. Address any underlying engine issues.
- Incorrect Part: Verify that the installed converter is the correct type and size for your vehicle and meets local emissions standards.
Image 7.1: A vehicle dashboard showing the speedometer and tachometer, with the 'Check Engine' warning light illuminated, indicating a potential issue.
Image 7.2: An image showing a cutaway of a damaged or clogged catalytic converter, contrasted with a new, intact converter, illustrating potential failure points.
8. Specifications
| Attribute | Detail |
|---|---|
| Brand | Walker |
| Model Number | 15038 |
| Manufacturer | Walker Exhaust |
| Item Weight | 4.8 pounds |
| Product Dimensions (L x W x H) | 15.8 x 8 x 5 inches |
| Inlet/Outlet Diameter | 2.5 inches (ID) |
| OEM Part Number | Mazda B33740300; Mazda B33740300A |
| UPC | 086387150385, 647367160550 |
9. Important Safety Information
Proposition 65 Warning: This product may expose you to chemicals including lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
Always wear appropriate personal protective equipment (PPE) during installation, including safety glasses and gloves. Ensure adequate ventilation when working in enclosed spaces, especially during welding or when exhaust fumes may be present.
10. Warranty and Support
For information regarding the product warranty, please refer to the official Walker manufacturer's warranty documentation or contact Walker customer support directly. Warranty terms and conditions may vary.