To test the heat of the exhaust system, put on a pair of heavy mechanic's gloves and gently brush the exhaust tube with the back of your hand. If you can't feel any heat, you may cautiously repeat this test without the glove. Locate the catalytic converter. Slide under the vehicle and locate the tubes of the exhaust system, which should run all the way to your vehicle's rear exhaust. The converter should not be terribly difficult to find — it will usually take the form of a rectangular or rounded "box" in the middle of your exhaust system.
Some models can have a roughly cylindrical shape. You may need to take it to an auto shop to have it repaired if it has already been replaced and welded back into position, rather than bolted.
You can still replace a welded converter if you have access to a sawzall or similar tool and a welding machine and know how to safely use both, but these advanced tools are beyond the mastery of most amateur mechanics.
Remove the O 2 oxygen sensor from the catalytic converter. Most modern catalytic converters are equipped with one or more oxygen sensors that monitor the efficiency of the car's exhaust system continuously. If your catalytic converter has an attached oxygen sensor, use an oxygen sensor socket and a ratchet wrench to disconnect it before proceeding. When you're done, move the sensor out of your way so that it doesn't interfere with the rest of the process.
If bolted, apply penetrating oil to the bolts. Catalytic converters that are bolted in can sometimes have bolts that are rusted, partially-corroded, or "jammed" into their nuts. These bolts can be very tricky to remove, so loosen them up by applying a penetrating oil available from most auto stores.
Allow the oil to seep into the bolts and lubricate them for several minutes before attempting to remove them. Remove the bolts at the back end first, then at the front. Use an appropriately-sized wrench to begin loosening all of the bolts before you start removing them. Once all of the bolts are loosened but still attached , remove the "rear" bolts those closest to the open end of the vehicle's exhaust before removing the "front" ones those further away.
Remove the converter when you're done. You may have to support the exhaust once the converter is removed. Alternatively, for welded-in converters, cut the converter out.
If your converter is welded into the rest of the exhaust system, rather than bolted in, the only way to remove it is to physically cut it out of the pipes it's connected to. Most mechanics will use a sawzall or similar tool for this purpose. Cut along or near the existing weld lines, then remove the converter after it's cut free. If you finish and the converter won't seem to budge, you may want to use a hammer to knock it out of its place as long as you take care not to damage or rattle any other parts of the exhaust system this can lead to harmful exhaust leaks down the road.
Part 2. Always defer to any included instructions. The instructions provided in this article are written for general cases of catalytic converter installation. When in doubt, always follow the instructions provided with your replacement part or consult the advice of a knowledgeable mechanic.
Converters have a specific direction they should flow and have an arrow for direction of exhaust flow. Insert any gaskets supplied with the new catalytic converter. Some converters, especially bolt-installed ones, will come with small, round gaskets that sit in the pipes connected to the converter to give the converter a snugger, more secure fit. If your replacement converter came with these gaskets, install them according to any provided instructions before proceeding.
Put the new catalytic converter in place. Next, hold the catalytic converter in the position where it will eventually be installed.
Double check to make sure it is pointed in the right direction there should be an arrow indicating this and that the correct side is facing down. Since it's tricky to work on the converter with one hand while you hold it in place with another, for the next few steps, it can be useful to enlist a willing friend to hold the converter in place while you work or use a stand to hold it up in place. Finger-tighten nuts on the bolts. If your vehicle's catalytic converter was bolted in and your replacement converter has bolt holes that match your exhaust system's, installation is usually a cinch.
To start, re-insert your bolts and use your hands to manually tighten them. This makes it easier to get all of the bolts to align correctly because the looseness gives you a small degree of "wiggle room" to make minor adjustments as needed. Tighten down all the bolts.
Starting on the "front" end of the converter the end further away from the vehicle's exhaust , tighten the bolts with a suitably-sized wrench. Proceed to the back end when you finish tightening the bolts on the front. You'll want your bolts to be very tight. Most exhaust leaks are caused by loose bolts, so making sure your bolts are extra tight now can save you headaches in the future. Alternatively, weld the converter into place.
If you need to weld your converter into place, the process is somewhat more involved. You'll need a professional-grade welding machine such as a MIG welder and the proper training and expertise required to use one safely or a friend who has these things. Don't attempt to weld your converter back into place if you're not a competent welder — you could damage your vehicle or even hurt yourself.
Weld your converter into place by carefully joining it to the exhaust system pipes at either end. Be sure to create a secure, air-tight seal at each weld. If the pipes aren't wide enough, you may need to heat them up and flare them to make them fit. If your pipes don't quite reach one end of your converter, you may need to weld an additional extender pipe in.
Sometimes you have to do a partial weld then lower the exhaust to finish the top part of the weld. Be sure to allow your welds to cool to a safe temperature before proceeding. A catalytic converter in your vehicle converts bad emissions into harmless gas. You should also replace the converter if you run into other apparent problems such as clogging, or physical damages. The team at Performance Muffler is committed to ensuring that your vehicle performs effectively by repairing or replacing the clogged catalytic converter.
Read on to find out when is the right time to replace a catalytic converter. The cat converts harmful substances such as toxic carbon monoxide and hydrocarbons into safe compounds like carbon dioxide, nitrogen oxides, and water.
Ideally, a catalytic converter ensures your car operates smoothly by nullifying harmful chemicals within the exhaust. Catalytic converters are designed to last for a long time.
For instance, spent spark plugs and coolant leaks exhaust leaks can lead to overheating of the catalytic converter. In other cases, soot buildup within the exhaust can interfere with the regular operation of the converter. One of the reasons why catalytic converters are included in cars is to reduce air pollution.
Exceptions are for older vehicles that were designed and sold without catalytic converters originally. The cost of vehicle repairs or parts replacement is dependent on several factors such as the type and model of the vehicle, the type, and quality of the parts to be used, as well as the location of the auto shop doing the service.
In all cases, there is the likelihood of some relatively small additional costs for gaskets and hardware. It is also fairly common to replace the O2 sensors with the catalytic converter. Ordinarily, they can be removed from the old part and installed in the new part the labor being included in the job cost. A vehicle with a large displacement engine moves more air and requires a larger capacity catalytic converter, while the reverse is true for a smaller engine.
This, then, leads to an unfortunately common issue. While an OE replacement catalytic converter will have the same capacity as the original and satisfy the expectations of the PCM, not all aftermarket cats are tested for capacity. The expensive part of a catalytic converter is the catalyst itself which incorporates precious metals in a matrix. Economizing on this saves costs, but decreases capacity.
It is possible then to buy and install a new cat, and after a short time, have the same fault code come back that leads to the replacement. This means that it has been tested and meets the strict California emissions requirement that a replacement converter has at least the capacity of the original part. In several states, this is a requirement. However, it varies from state to state and year to year as well. Universal catalytic converters are generally only installed at muffler shops that have the proper pipe-forming and welding equipment.
Non-certified parts are usually bolt-on replacements that most shops could install. Though, if the part works without issue for the first month or two, that usually means it will be fine for the long term.
While they can cause issues, the cost savings are usually significant where it can legally be done. In most cases, an engine light will be the only indication of catalytic converter failure; the codes P and P being the common ones.
The general rule for diagnosis is to repair any other engine fault codes first, rule out exhaust leaks, verify if the converter fault is persistent, and then, replace the catalytic converter.
Most of the time, the catalytic converter is a bolt-on part and not too hard to access.
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