LS6 Revolution: Pups Out, New Cats In
The key enabler for the cam and everything else to work
to the tune of 20 more horsepower was a revolutionary, new catalytic
converter design.
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During
the ’02 Z06 press conference at Irwindale Speedway, John
Juriga (at left) and Dave Hill explained a key enabler for
the LS6 engine’s extra power was a new catalytic converter
design that reduced exhaust restriction. Image: Author. |
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Last May, The Idaho
Corvette Page interviewed Corvette Chief Engineer, Dave Hill,
and John Juriga. Even before I fielded my first question, Hill made
a statement refuting charges by some conspiracy theorists that GM
has been delaying introductions of high-performance Gen III’s to
enhance marketing.
"We never set out to obsolete the 2001 (LS6)" Hill
told . "The horsepower increase was possible only after we
completed a lengthy development of a new catalyst. I want to set the
record straight: the 2001 was the best Z06 we could possibly
make and 2002 is better because new catalyst technology let us get
the back pressure down, increase the breathing and make that power
increase." |
"In 2000," John Juriga added, "we
had to meet the LEV standard here in California, so we added close-coupled
convertors up front (of the regular cats) on the California package–our
"pups" as we call ’em. In 2001 we carried those pups
across-the-board, including on the LS6. Even while we were implementing
that, we were working on a design that would eliminate those pups. This
reduced back-pressure by two inches of mercury. On its own, that was worth
about 5hp. That seems not much but, if you reduce back-pressure by even
small amounts; you can make a bigger gain with improvements on the
induction side, especially with the cam."
Catalytic converters (aka "catalysts" or
"cats") must reach and sustain a high interior temperature for
the reaction necessary for the conversion of exhaust pollutants to occur.
The period between engine start and cat "light-off" is the most
difficult time from an exhaust emissions standpoint because the cat isn’t
hot enough to work.
The Corvette "under-floor" cats were the same
from MY97-01. To meet California LEV for MY00, Juriga’s team of
engineers at GM Powertrain Division (GMPT) had to make cat light-off
happen sooner and the solution for ’00 California cars and all ’01s
was to move the catalytic reaction closer to the exhaust heat by adding
small, close-coupled, catalytic convertors, or "pup cats",
upstream of the under-floors and closer to the exhaust manifold outlets.
While the official ratings did not change, ’00 California cars were
probably about 5hp short of the ’97s, ’98s and ’99s because of the
pups. MY01 had no deficiency because the LS1 was changed in other areas
negating the pup’s power loss.
Engineers call the interior structure, or
"substrate," of a catalytic converter a "brick"
because of its characteristic shape. The ’97-’01 under-floor cat used
a single brick having a combination of palladium and rhodium as its
reactive ingredients. The ’02 under-floor is a two-brick design. The
front brick uses palladium and the rear brick uses a platinum-rhodium
combination.
This new cat, along with changes in PCM calibration,
allows the LS6 to meet LEV without pup cats and their exhaust
back-pressure. There were other benefits of going pupless, too: less cost
and a 5.5lb. weight reduction.
Anyone planning to upgrade an ’01 Z06 to ’02 specs
is going to have to do more than just change the camshaft and valve train
to get the full 20hp increase. They will need to remove their pups and
upgrade to the ’02 under-floor cats. If that’s not done, they’ll see
only part of the increase.