This is just my thought, but...
I think the answer of the exhaust manifold fitment is just a canard, something made up by the marketing department. From the engine engineering point of view, here's what's more likely going on. The current trend for emissions control is what's called a "close-coupled" three-way catalyst. This places the cat as close as possible to the exhaust ports so that heat loss is minimized in order to get the cat up to light-off temperature as quickly as possible. Almost ALL of a car's HC emissions take place during the cold running phase before the catalyst lights-off; beyond that, conversion efficiencies are almost 100% and therefore the remaining 95% of the drive cycle is pretty much irrelevant to HC emissions.
A long primary header is precisely the opposite of what you would want to achieve from the standpoint of placing the cat as close as possible to the exhaust valve. I showed
here that the Japanese
JC08 test cycle is relatively undemanding compared to the US'
FTP75+
US06+
SC03. Also, Japanese regulations limit HC emissions at 0.024 g/
km, whereas US T2B5 is 0.015 g/
mile (converted, 0.0093 g/km). Despite the different test cycles, strictly on a quantity basis, T2B5 is still over 60% more stringent than the Japanese limits.
Mazda must have been extremely optimistic to assume that the design for the Sky-G's exhaust manifold and catalyst, which could meet Japanese regulations, could also meet T2B5 with only trivial changes.
I don't buy for a second the fitment argument. No OEM company can be so short-sighted not to develop one component like an exhaust manifold for a forecasted model application. I can go out and buy an
aftermarket header for a Mazda3, which still allows me to retain a catalyst, and be done with it.