- How To Fix A Catalytic Converter (Without Replacing It)
- Replacing Catalytic Converter Without Welding
- How To Install Universal Catalytic Converter Without Welding
- How To Put A Muffler On Your Car Without Welding? | It Still Runs
Ever wondered how do vehicles minimize the pollution from their emissions?
- Universal catalytic converter on '04 Chevy Impala MD Free. No welding - Duration: 17:07. Ed The Impala Guy 3,842 views. O2 Sensor Impala Full Install - Duration: 11:22.
- Catalytic Converter Overall Length: 16'. If your car needs a new catalytic converter, install one that will get you through the smog check. This universal fit converter will require some fabrication to be installed, which will involve cutting the exhaust pipe and may require welding.
- This type of universal catalytic converter is not a great solution for small cars that have the catalytic converter up close to the exhaust manifold. Tools needed are a Sawzall or angle grinder with a metal blade and some wrenches for the clamps. Some universal catalytic converter install notes. The Magnaflow catalytic converter in the video.
Well, a device called catalytic converter converts the pollutants into eco-friendly or harmless gases. The major vehicular pollutants are carbon monoxide, hydrocarbons, and heat generated gases (nitrogen oxides).
A catalytic converter uses a catalyst in the form of platinum or palladium which converts these harmful gases into harmless gases.
Over a period, the catalytic converter loses its functionality and needs replacement. Therefore, let us know how to replace and install a catalytic converter for your vehicle.
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What is a Catalytic Converter?
A catalytic converter is a mechanical device inserted in the emission system of vehicles that use gas. It forms a series of reduction and oxidation (redox reaction) reactions which reduce the hazardous emissions from the vehicles.
French mechanical engineer Eugene Houdry was the pioneer in commercializing the catalytic converter. He studied the effect of smog (smoke + fog) on the environment and was concerned about the impact of vehicular pollution on the environment.
The Catalytic Converter Has The Following Components:
- A substrate or support for a catalyst which is made of ceramic or an alloy (iron-chromium-aluminum). The catalyst support is designed in the form of hexagonal rings to form a honeycomb structure. Honeycomb structure results in the larger surface area.
- Oxides of Aluminum, titanium, and silicon are used as washcoat. These oxides or washcoats dispense the catalytic material over a large surface area.
- Solid source of oxygen which does not decimate to heat. Most of the catalytic converters use an oxide of Cerium, a rare earth metal.
- The final component of the converter is the catalyst. Precious metals such as Platinum, Palladium, Iridium, and Rhodium are commonly used as catalysts.
- Palladium and rhodium are most commonly used as oxidation and reduction catalysts respectively. Platinum is a very active catalyst (for both reduction and oxidation) but is not applicable due to its high cost.
In summary, a honeycomb ceramic structure (alloy comb for high heat emissions) is coated with washcoat, oxygen dispenser, and catalyst which in turn is inserted into the exhaust system of the vehicle.
How Does a Catalytic Converter Work?
The catalytic converter works by two significant reactions:
- Reduction
- Oxidation
The nitrogenous emissions are reduced (removal of oxygen) to nitrogen and oxygen. Nitric oxide (NO) and Nitrogen dioxide (NO2) are the major nitrogen compounds from fuel combustion which cause acid rains and smog.
On the other hand, an oxidative reaction will add oxygen to carbon monoxide (CO) and turn it into carbon dioxide (CO2). It also turns hydrocarbons into water (H2O) and Carbon dioxide.
In total, three reactions are happening in a catalytic converter, and hence it is called as three-way conversion and so the converter as a three-way catalytic converter.
Catalytic converters used in gasoline vehicles are three-way catalytic converters whereas those used in diesel vehicles are two-way converters.
Conversion of hydrocarbons is omitted in diesel engines because they do not emit much heat as gasoline engines do.
When to Replace a Catalytic Converter?
In general, catalytic converters have a very long lifespan. They can last up to 10 years. But there are sure signs which indicate that you have to replace them. These signs are:
- Clogged exhaust
- Overheating under the body of the vehicle
- Significant reduction in the vehicle’s acceleration
- A foul smell (rotten egg) from the exhaust
Some of these signs can happen due to other reasons such as engine coolant contamination or physical damage to the exhaust vent.
A technical guy will be able to diagnose appropriately and would suggest you to change the converter if needed.
How to Replace and Install Catalytic Converter?
Once you have decided to replace and install the catalytic converter, get all your gear that are necessary for the process. The tools required for this process are:
- Wrenches
- Ratchets
- Ratchet extensions
- Racket joints
- Safety gloves and glasses
- Jack and jack stands to elevate the vehicle above the ground
- Sawzall or any other cutting tool for removing a welded converter
- Penetrating oil to loosen up the bolts and nuts of the converter which usually get rusted
Steps In Removing The Catalytic Converter
The first step is to raise your vehicle so that you can move freely beneath the vehicle. Raise the vehicle to your comfort level and secure it with jack stands.
Do not forget to engage the hand-brake. If you are using a manual vehicle (geared), you can further secure the movement by putting the vehicle in gear.
Locate the Converter
Once the vehicle is raised, locate the catalytic converter. It is usually placed just before the exhaust pipe. Some vehicles may have multiple converters, and you have to locate the converter which you are intended to replace.
Remove the Sensor
After finding the converter, remove the oxygen sensor from it. Some oxygen sensors are mounted over the converter while some are inside it.
Use the appropriate wrench or ratchet to remove the sensor. If there is no oxygen sensor, you can proceed to the next step.
Remove the Converter
Now, it is time to remove the catalytic converter itself. Most converters are bolted to the exhaust. These bolts will usually get rusted over time. To remove the rusted bolts, use a penetrating oil.
Spray/pour the penetrating oil over the bolts and let them soak for few minutes.
The penetrating oil will make it easy to remove the rusted bolts by penetrating between the threads of the bolt (lubricating action). After lubricating the bolts, use assorted wrenches suitable for the bolt size and remove them carefully.
You may require extension joints or shoulders depending upon the location of the converter and the bolts on it.
For welded converters, use the Sawzall or any other similar to cut off the converter from the exhaust manifold.
Steps For Removing A Built-In Catalytic Converter
Certain vehicles have catalytic converters which are installed directly to the engine (cylinder heads). Locate the converter under the hood which is built into the engine.
The built-in catalytic converters are usually bolted (not welded) to the cylinder heads.
Locate the bolts and use penetrating oil if necessary. Use suitable assorted wrenches and remove the catalytic converter.
Steps For Installing The Catalytic Converter
After you have successfully removed the old catalytic converter, just follow the steps of removal in reverse mode.
- It is advised to follow the instruction manual supplied with the converter. Position the gaskets (if present) in an appropriate position. These gaskets connect the converter to the exhaust unit or cylinder head (for built-in converters).
- 2Tighten up the bolts with your hands first to hold the converter in position. Once in place, tighten up the bolts with assorted wrenches. Make sure there is no wobbling or shaking of the unit. A loose fit will affect the engine pick up as well the emission.
- If your catalyst converter is a welded one, re-weld it again appropriately. The pipe ends of both converter and the exhaust must be sealed air-tight. If the pipe length is less, you can weld an additional pipe to fill the void.
- 4Make sure to take all precautions during the welding procedure. Equip yourself with welding helmet with side shield, clothes that are fireproof, respirators, ear protection, gloves, and shoes.
- After installing the converter, replace the oxygen sensor in its previous position and tighten up its bolts as well.
Re-check all the steps you have and make sure they are perfect.
Frequently Asked Questions (FAQs)
How often should I replace the catalytic converter?
A catalytic converter will last long, and it does not require frequent replacements. If you are in doubt, take professional help.
What are the general precautions to be taken while replacing a catalytic converter?
Make sure your vehicle is secured over the jack stands. Always wear protective gear such as gloves, eye, and ear protection while doing the job. If you are unsure about the procedure, seek technical help.
Is it okay to replace one catalytic converter if the vehicle has multiple converters?
It is fine to replace one (damaged or non-functional) catalytic converter if your vehicle has multiple units.
Bolt's won't turn, what should I do?
Spray the penetrating oil and leave it for at least five minutes. It will lubricate them, and you will easily remove them.
Conclusion
The procedure of replacing and installing a catalytic converter varies from vehicle to vehicle. This guide is a general guide, and it is always good to follow the instruction manual.
The overall procedure is the same for all vehicles except for the type and location of the converter and the presence of the oxygen sensor.
If you are unsure about the procedure, get it done by a professional.
A catalytic converter in the exhaust system of a motor vehicle is essential in making exhaust fumes less harmful. Although this device is simple, it carries a huge impact on how a vehicle may operate.
If a catalytic converter failed, it must be replaced. However, paying car dealerships to replace and fix your car for a catalytic converter failure can be quite a dent in your pocket. But there are other options like gathering your set of hand tools and doing it yourself. In this article, we will cover the steps on how to install a catalytic converter.
Symptoms of Failed Catalytic Converter
Table of ContentsBefore you fix and replace anything, you have to know why exactly you have to do it. Does your car suffer from reduction of engine performance? A clogged converter restricts exhaust flow that can result to a poor engine performance and also creates rattling noises when it becomes old and damaged. A failing converter can also cause increased emissions.
If your car have these symptoms, it is best to have your vehicle inspected by a professional technician to determine if it needs the catalytic converter replaced.
Selecting the Best Catalytic Converter
Before you replace any old and battered catalytic converter in your vehicle, you have to buy the right replacement for it.
First thing, before purchasing any converter replacement, it is important to know what type of emission system your vehicle originally came with. Check for your emission equipment sticker, this can be found either under the hood of your vehicle or behind the engine.
Where is your vehicle registered in? There are certain standards that the catalytic converter of your vehicle has to meet depending on where it is registered in.
There are two types of catalytic converter you can buy. A direct fit catalytic converter is designed to match the old converter from your vehicle. You can bolt it directly into place during your installation. There is also the universal catalytic converter if the direct fit converter is not available which costs less but this will need a little more effort to install. You have to actually measure your existing exhaust and might have to weld it into place taking extra care in fitting the right sensor ports.
How to Install Catalytic Converter
Catalytic converters are most commonly secured in two ways. It is either bolted up at the flange or is welded directly at the pipes of the exhaust system. Though replacing catalytic converters may vary from different types of vehicles, we will cover the most common bolt-on type that can be done with enough knowledge and the right kind of tools.
READ:Fenix E05 2014 Black Flashlight ReviewSteps on How to Install a Catalytic Converter
Raise your vehicle and secure it on jack stands. Make sure to raise it to have enough space for working underneath the vehicle.
How To Fix A Catalytic Converter (Without Replacing It)
Find and locate the catalytic converter under your vehicle. Catalytic converter is part of your exhaust system so you will most likely find it in the system itself.
Remove any oxygen sensor, if any, that may be attached directly or near the catalytic converter.
Spray penetrating oil on the flange hardware of the exhaust to break it more easily, since it is prone to rust because of its location under the vehicle. Let it sit for minutes before loosening it up with a wrench.
Replacing Catalytic Converter Without Welding
Replace the catalytic converter with a new one. Also, replace any exhaust flange gaskets to avoid any exhaust leaks. Install the new catalytic converter by reversing the steps.
You may also want to follow the How to Replace Catalytic Converter video if you want a more visual step in replacing a failed catalytic converter.
How To Install Universal Catalytic Converter Without Welding
Testing the New Catalytic Converter
After replacing and installing the new catalytic converter in your vehicle, it is best to take the car out for a test drive. Look for any leaks from the exhaust of your vehicle while it is running. Most leaks are caused by loose bolts on the flange of the converter. So, if you see leaks while running your vehicle, turn the engine off and let it cool. Re-tighten the bolts until it is necessary.
Tips in Replacing Catalytic Converter
The steps in replacing and installing a failed catalytic converter are quite easy to follow. However, it is a good idea to determine either before or after you replace the converter to know the reason why the original converter failed. This will help you to correct the causes of failure to avoid the same thing happening again.
Dealing with a failed catalytic converter in your vehicle and having to replace it can be quite expensive depending on the type of vehicle and where you go to get it fixed. However, if you have the right knowledge on how to install catalytic converter, you can even save a hassle by doing the work yourself.
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