Repair And Fix it

The catalytic converter happens to be one of the most expensive parts of a car to fix, which leads many people to try to repair it at home. You have to know your way around cars and exhaust systems, or youre honestly better off taking it to a mechanic. If youre comfortable working on it yourself, there are a few things you should keep in mind.

Instructions

1

Lift your car. Unfortunately, the catalytic converter sits about midway down the length of your car, so lifting one end or the other will not do. Ramps are your best bet to get you within reach of the parts when working from home. Luckily, this is usually the hardest part of this repair.

2

Be patient with the bolts, as they are often hard to remove due to size and awkward placement. You may have to drill or saw bolts to remove them. With this in mind, you should pick up new bolts, nuts and seals for your replacement project.

3

Buy a catalytic converter specific to your car to avoid extra work. A generic part must be welded into the car, while a vehicle-specific model comes pre-welded to the proper pipes for easy bolt-on installation.

4

Remove the 02 sensor (with an O2 wrench) before unbolting the catalytic converter. Then, you should remove the pipe connecting the sensor to the converter. Depending on your exhaust system, you may have to remove more pipes before you unbolt the converter from the muffler.

5

Replace the old catalytic converter with a new one. This should be the easy part, as you simply bolt the new part in place.

6

Reattach the exhaust pipes and 02 sensor, and the basic job is done. Make sure you replace any cracked or rusty pipes while you have the exhaust system apart.

While a catalytic converter is designed to last 10 years or more, several variables can make it die sooner. Nowadays, vehicles employ more than one converter, which increases the chances of internal or external problems. When catalytic converters were integrated for emissions control, they converted harmful hydrocarbons and carbon monoxide into cleaner emissions. Three-way converters are now used to additionally control and convert nitrogen oxides. Oxygen sensors now monitor the efficiency of each converter on every vehicle.

The External Converter

The external shell and attachments of the catalytic converter is relatively simple to monitor. If damage occurs to the external components, the exhaust will leak from the compromised shell and emit a loud noise. Premature damage to the converter can occur from undercarriage incidents. Also pipe connections or flange connections are common areas that deteriorate from age and existing in hostile environments. Not only will the noise alert the driver that there is a problem with the converter, but performance issues can arise from an external exhaust leak from the catalytic converter. Lower exhaust back pressure can cause engine performance problems as well as trigger the oxygen sensor monitoring the converter to misread the information its designed for.

The Internal Converter

The average temperature an exhaust system operates under is 1,200 to 1,600 degrees Fahrenheit. The internal structure of the converter is made of platinum and palladium honeycomb that filters and chemically alters the exhaust emissions. As pollutants increase in the exhaust, so does the operating temperature of the internal structure. At 2,000 degrees Fahrenheit, the structure will begin to weaken or melt, reducing its efficiency to convert harmful gases into less harmful pollutants. The platinum and palladium honeycomb will begin to melt into the ceramic substrate. When this occurs, the structure can break down or clog the converter, which results in little to no back pressure flow through the converter.

The oxygen sensor will fail to register the efficiency of the converter and transmit the communication to the computer of the vehicle. In addition, little to no back pressure will result in a poor-performing engine. When exhaust is prohibited from exiting the combustion engine properly, it will choke on its own exhaust or stop altogether.

Engine Performance

Rarely does a converter break down internally on its own. Replacing a clogged or compromised converter may simply mean placing a bandage on a gaping wound. Exhaust from a combustion engine expels and recirculates unburned fuel and oxygen necessary to allow the engine to operate properly. A perfect fuel-to-air ratio exists for a combustion engine to function, and when that ratio is compromised, other components in the engine and exhaust system can and will fail.

Unburned fuel is a leading contributor to causing a catalytic converter to fail internally. So replacing the converter only temporarily solves the problem. When the engine is not performing as it should, its only a matter of time before it damages the new converter. Diagnose any and all diagnostic trouble codes before replacing a catalytic converter to preserve and enhance its performance and effectiveness.

Catalytic Converter Removal

In order to remove titanium material from inside a vehicles catalytic converter, the converter must first be removed completely from the vehicles exhaust system. Normally, catalytic converter removal is accomplished by unscrewing the bolts that bolt a converter to the exhaust system or by cutting off the converter with a saw or welding torch. Complete removal of a catalytic converter from a vehicle allows easy access to its inner catalyst material--the part that contains the titanium pieces. After removing the titanium pieces (along with the catalyst material), the catalytic converter is no longer legal for vehicle use and must be discarded.

Removal of Catalyst Material

After removing a catalytic converter from a vehicle, the next step toward removing the inner titanium pieces is to remove the catalytic converters catalyst material thats located deep inside the converter. These catalyst pieces, which look very similar to small pieces of charcoal, are the parts of a catalytic converter that burn the unburned exhaust gases as exhaust flows through a catalytic converter. These pieces can be removed simply by standing the catalytic converter lengthwise up--one open end facing up, the other end facing the ground--and tapping and pounding on the raised end until the catalyst pieces start to fall out of the bottom end. This process normally takes only a few minutes to retrieve all the pieces.

Manual Removal of Titanium Pieces

After the catalytic converter catalyst material has been removed from inside, the titanium--which is used as a coating on the catalyst material--can easily be removed. The titanium normally appears as a silvery bronze coating atop the catalyst pieces. It can be scraped and/or gouged off each individual titanium piece by using a small knife, spoon or small instrument. A small rag or cup can be used to gather the removed titanium pieces. This can take quite awhile on some of the larger, more expensive catalytic converter models with large amounts of both catalyst material and titanium coating.

Toyota Rav4s have two catalytic converters. The front one is bolted directly to the manifold in the front of the exhaust system and the second one bolts directly to that. In most cases, the converter that fails will be the rear converter. Converters fail after a while clogging, breaking down internally (which is a result of clogging and overheating), and have inlet or outlet pipes that crack or leak exhaust. Having to replace them requires experience.

Instructions

How to Replace a Toyota Rav 4 Front Catalytic Converter

1

Put the Toyota Rav4 on a car lift and bring all the way up. Put all the listed tools into the tool cart and wheel it near you where its out of the way but where you can access the tools easily. To remove the five nuts going to the manifold, set up the ratchet with a long extension, the swivel, and a socket. In some cases if the nuts are deteriorated, you may need to switch the socket for a nut extractor.

2

Put on the safety glasses and light the torch with the striker. Heat up the nuts with the torch, being caul not to heat the studs up as well. Its a tight area and youll have to know how to handle a torch and adjust the level of flame to be small enough to do the job but hot enough succeed. When the nut is cherry red in color, turn off the torch and remove it with the ratchet, extension, swivel, and socket or nut extractor. Carry on this procedure for the other four nuts.

3

Light the torch and cut the two or three bolts (some of the rear converters have a three-bolt inlet and some have two of the Rav4s) out of the rear flange. Cut them from the front converter side so you do not incur any damage to the rear converter. When the bolts are cut with the torch flush to the flange, turn off the torch, put on the safety gloves, and knock the rest of the bolt from the flange with a punch and hammer. Be ready to get out of the way or catch the front converter as it will drop out as soon as its free.

4

Allow the system to cool down. Install the top of the front converter with a new gasket to the manifold by threading on some new nuts by hand. Tighten them one at a time with the pneumatic gun, extension (either small or long), swivel, and socket until theyre tight.

5

Insert the gasket to the rear of the front converter flange connection and attach with the hardware (bolts, nuts, washers). Tighten with the gun, the small extension (if needed), swivel, and hold the head of the nuts in place with a hand wrench. Remove the cart and tools and any debris on the floor, lower the Rav4, and start it up to check for any possible exhaust leaks.

How to Replace a Toyota Rav 4 Rear Catalytic Converter

6

With the Rav4 raised on a lift, locate the oxygen sensor bolted to the rear converter. Follow the wire to the plug and separate it by unplugging it. You may need the screwdriver to press in the clip lock. As with the front converter, load the tools into the cart and have nearby.

7

Put on the safety glasses and light the torch with the striker. Cut the bolts from the front flange connection with the torch. Cut them from the rear converter side of the flange to avoid damage to the front converter flange. When the bolts are cut flush to the flange, turn off the torch and knock them out with a punch and hammer. Repeat this step for the rear converter to rear exhaust pipe flange. Be caul when the last bolt gets punched through. The converter will want to drop, but youll notice its still affixed to a rubber exhaust hanger. Remove the hook of the converter from the hanger.

8

Remove the bolts from the oxygen sensor studs. They may be deteriorated and you may need the extractor nuts to help you. Dont worry about the nuts or studs and damaging them. Youre going to replace the nuts and the studs are part of the converter. There will be new studs on the new converter. All you need is the oxygen sensor.

9

Insert the oxygen sensor into the new converter. Replace gasket (equipped with new converter) and nuts and tighten with the ratchet, extension, and a socket.

10

Place the hook on the new converter through the rubber hanger and attach the front flange to the front converter with gasket and hardware (bolts, washers, nuts). Attach the rear flange of the converter to the rear exhaust pipe flange with the gasket and hardware. Tighten the bolts and nuts with the gun, swivel, socket, and a hand wrench. Plug the oxygen sensor back into the plug. Remove the cart, tools, and any debris, lower the Rav4 and start the engine to check for any possible exhaust leaks.

Every car sold in the United States is required to have a catalytic converter. The catalytic converter is an essential part of your cars emissions system. No matter which option package or engine your Eclipse has, changing the catalytic converter is going to be accomplished the same way. The 1995 Eclipse has a a three-way catalytic converter, named as such because it converts nitrogen oxides into nitrogen and oxygen, carbon monoxide into carbon dioxide and unburned hydrocarbons into carbon dioxide and water vapor.

Instructions

1

Park the car and firmly set the parking brake. Block one drivers side wheel, front and back. Place the jack under the middle of the passenger side, directly below the frame, and lift it high enough to crawl under safely. Place the jack stands under the front and rear sections of the frame and lower the car onto the stands.

2

Spray the bolts on the flanges, on either end of the catalytic converter. Remove the nuts and bolts from both front and rear exhaust flanges on the catalytic convert exhaust pipes by turning them counterclockwise, using a ratchet and socket and a wrench. Remove the converter.

3

Clean the exhaust pipe flange mounting surfaces completely, using the wire brush.

4

Hold one end of the converter in place and insert a gasket between flanges, and reinstall the nuts and bolts, turning them clockwise by hand and tightening them with the ratchet and socket and a wrench.

5

Repeat Step 4 on the other flange and gasket. Start the car and spray both flanges with the soapy water and check for bubbles. Tighten the flange if you see bubbles.

6

Roll the jack under the middle of the frame, raise the car off the stands and remove the stands. Lower the car and remove the jack and wheel blocks.

A catalytic converter helps to remove certain pollutants from the car exhaust, rather than releasing those pollutants into the air. The catalytic converter sits in the car exhaust system, behind the exhaust headers and before the car muffler. Normally, a catalytic converter will last the life of a vehicle, unless an underlying problem causes it to fail.

Emissions Test Failure

A failed catalytic converter that has not clogged can contribute to an increase in hydrocarbons and carbon monoxide exiting the car tailpipe. Normally, the catalytic converter will reduce the amount of these pollutants to extremely low levels. An increase in these pollutants in the car exhaust can also be caused by a faulty air pump, pulse air system or another component of the car air supply.

Fuel Mileage

A catalytic converter that has plugged up will create excessive back pressure in the car exhaust system. This back pressure increase can affect the car fuel mileage, meaning the car will not be able to drive as far under the same conditions with the same amount of gas. The plugged catalytic converter causes the car to work harder to maintain performance, meaning the car engine will burn more fuel than it would if it had a properly functioning catalytic converter.

Engine Power

A plugged catalytic converter can also reduce the car power at high speeds, such as when the car is driving on the freeway. The driver may notice the car cannot pass other vehicles on the road at freeway speeds as it once did. A driver may also notice that, once the car hits a certain speed, its acceleration becomes sluggish. A plugged converter can also cause the car to idle rough, meaning the engine will sputter or fluctuate in its RPMs. The failed catalytic converter can also cause the car to have trouble starting, causing the engine to stumble or stall upon starting.

The catalytic converter collects the exhaust waste from the engine and reduces as many pollutants as possible. The converter on a Vibe is bolted to the exhaust manifold, but welded to the exhaust pipe. If you need to replace the converter on your Vibe, experience in cutting and welding is essential. Please note that federal law mandates an extended warranty on all exhaust components, so it may be easier and cheaper to have the converter replaced professionally. The process can also vary greatly depending on the model year.

Instructions

1

Raise the Vibes rear end with a floor jack and support it on jack stands. The catalytic converter looks similar to the muffler, but is located closer to the engine.

2

Apply penetrating oil to the nuts and studs connecting the converter to the exhaust manifold.

3

Unscrew and remove the nuts on the front exhaust flange with your wrench and separate the front end from the exhaust manifold.

4

Dress in long-sleeved, flame retardant clothing, along with a full protective welders mask, and cut the rear end of the catalytic converter from the Vibes exhaust pipe using an acetylene cutting torch.

5

Install the replacement converter to the exhaust flange using the nuts and your wrench.

6

Weld the catalytic converter onto the rear exhaust pipe with your welding torch.

7

Lower the car off the jack stands once the weld is cool and solid.

Catalytic converters are designed to capture particulates from the exhaust of your car or truck and filter them out so that your vehicle doesnt have poor emissions. Over time, they can go out and will need to be replaced, otherwise you wont pass your local emissions tests. Unfortunately, there isnt a bolt-in replacement for a 1993 Bronco, and you have to remove the old one by cutting it out, then welding in a new one. Cutting out the old one can be done at home with the right tools.

Instructions

1

Crawl underneath the SUV and locate the catalytic converter. Its shaped like a square with rounded corners, and is around the door area underneath the cab.

2

Place the hearing protection, eye protection and gloves on. Then place the metal reciprocating saw blade in the end of the reciprocating saw. Cut the exhaust tubing approximately 2 inches from the end of the rear facing portion of the catalytic converter using the reciprocating saw.

3

Cut the forward facing portion of the exhaust, about 2 inches in front of the catalytic converter using the reciprocating saw. When youre just about to finish the cut, move out of the way so that youre not underneath the converter, as it will fall to the ground.

Replacing the catalytic converter on your Firebird can improve fuel economy, engine performance and drivability. Catalytic converters are not prone to failure but when they do go bad, they will run very hot and can choke off the flow of exhaust from the engine. Replacement converters are available from several sources including automotive parts stores or the dealers parts department. Some salvage yards or parts recyclers also stock good used converters at discounted prices.

Instructions

1

Raise the front of the car with a jack and position a set of jack stands under the frame to support the car. Locate the catalytic converter under the passengers side of the car.

2

Remove the retaining bolt on the exhaust clamp at the rear of the catalytic converter with a wrench. Move to the front of the converter and remove the four bolts from the mounting flange between the front of the converter and the exhaust pipe with a socket and ratchet.

3

Lower the converter down and move it out from under the car. Discard the old converter.

4

Position the new converter under the car and raise it up into position. Slide a new gasket in between the front flange on the exhaust pipe and the flange on the converter. Install the four mounting bolts and tighten them with a socket and ratchet.

5

Install the exhaust clamp on the rear of the converter and tighten the retaining bolt with a wrench or socket and ratchet. Do not over tighten the bolts; the pipe will deform causing an exhaust leak if this bolt is too tight.

6

Raise the front of the car off the jack stands with a jack. Remove the stands from under the front of the car and lower the jack.

Complete Removal of Catalytic Converter From Vehicle

In order to extract the platinum from within a catalytic converter, the converter must be removed completely from the vehicle. Most catalytic converters simply bolt on to a vehicles exhaust system with a series of threaded bolts. Loosening and then removing these bolts with a simple socket wrench allows for a catalytic converter to be pulled (removed) from a vehicle. If time is of the essence, a cutting torch can be used to simply cut the metal attachments linking a catalytic converter to a vehicles exhaust system, allowing for fast catalytic converter removal.

Removal of Catalytic Converter Catalyst Material

Platinum, which is used as a catalyst accelerant material inside most modern catalytic converters, is located deep inside a catalytic converter. It serves as coating on top of the main catalyst elements. The elements that ignite incoming exhaust gases that pass through a catalytic converter, otherwise known as catalyst elements, look like chunks of burnt charcoal. These catalyst pieces, which become white-hot in response to incoming exhaust gases, are coated with platinum to speed up the rate at which they heat up and burn exhaust gases. To remove the platinum coating on the catalyst pieces, the catalyst pieces must be removed from the converter. This is done simply by turning up the catalytic converter lengthwise and pounding on one end with a blunt instrument until the catalyst pieces start to fall out of the lower, open end of the converter.

Platinum Coating Removal

Once the platinum-coated catalyst material has been removed from a catalytic converter, the platinum can be removed from each individual piece of catalyst. The platinum, which appears as a silvery, bronze color located on the outer surface of each piece of catalyst, can be picked and peeled off by hand or by using a flat-head screwdriver or pair of box cutters. The platinum normally flakes off in small pieces or nuggets. As each piece is chipped off, it can be set aside and placed on a clean towel or rag. Complete platinum removal from the converter catalyst material should take 30 to 45 minutes for a standard-sized catalytic converter.

Removing the catalytic converter from the exhaust system of your Jeep Cherokee takes just a few minutes and requires minimal tools. Replacement converters are expensive so you may want to consider purchasing an aftermarket unit instead of an original equipment manufacturer (OEM) one as a cost savings measure. Replacement converters are available from your local Jeep dealership or most auto parts stores.

Instructions

1

Raise the front of the Jeep Cherokee off the ground with a jack then position a set of jack stands under the front suspension to support it. Slide under the passengers side of the Jeep and locate the converter in the exhaust. The converter sits near the center of the Jeep, between the frame rails.

2

Locate the rear mounting flange between the catalytic converter and the muffler. Remove the nuts from the retaining bolts with a wrench then remove the bolts from the flange. Separate the muffler from the converter and push the muffler aside.

3

Remove the nuts from the retaining bolts that secure the mounting flange at the front of the converter with a wrench. Remove the bolts from the mounting flange and set them aside.

4

Separate the converter from the front exhaust pipe. Lower the converter and slide it out from under the Jeep.

A catalytic converter can become clogged over time and need to be replaced. A clogged converter will cause a lot of back pressure in the engine, which results in poor fuel economy and loss of power to the engine. Your 1991 Buick will feel like its struggling when you need the power the most. The catalytic converter can be easily removed from the car, and the process only takes about 30 minutes.

Instructions

1

Park your Buick on a level surface and set the parking brake.

2

Place a wheel chock in front of one of the front tires.

3

Raise your Buick with an automobile jack and place a jack stand under the vehicles frame near a jack point for safety.

4

Remove the connecting bolts from the front end of the catalytic converter with the proper sized wrench and remove the bolts from the back end.

5

Remove the catalytic converter from the exhaust system.

An automobile catalytic converter is an automobile part designed to minimize the toxins emitted as a result of the combustion of fuel.

HIstory

The first production catalytic converter was made in 1973 by Engelhard Corporation and began appearing in U.S. automobiles in 1975. The development of catalytic converters was part of the automobile industrys efforts to meet stricter air quality standards laid out in the 1970 Clean Air Act Extension.

Types of Pollutants

Automobile catalytic converters are designed to reduce three types of pollutants: carbon monoxide, hydrocarbons and nitrogen oxides. These chemicals contribute to smog and are harmful to humans.

Components

The typical catalytic converter consists of a can, which houses the catalytic converters working parts, and the substrate, a honeycomb of ceramic or stainless steel coated with a metal catalyst, such as platinum, rhodium or palladium.

Process

The emissions pass into the catalytic converter, where gases come into contact with the large surface area of the honeycomb. The nitrogen oxide in the exhaust reacts with the metal catalyst, breaking down that compound into its less harmful parts. Additionally, carbon monoxide reacts with the metal catalyst and oxygen, resulting in carbon dioxide.

Other Functions

In modern automobiles, the catalytic converter plays an additional role in helping the engine run as efficiently as possible. An oxygen sensor located in the catalytic converter communicates with the engine how much oxygen the engine has burned, allowing the engine to adjust the air-to-fuel ratio so as little fuel as possible passes through the engine unburned.

Catalytic converters are small, muffler shaped containers filled with platinum mesh screens that remove toxins from exhaust. In time, a catalytic converter will fill with deposits that stop exhaust from flowing to the muffler and out the tailpipe. When a catalytic converter gets plugged, the only way to unplug it is by removing the mesh screens that are blocked with deposit material. Unplugging a catalytic converter is easy, but there are regulations in some areas against operating a street vehicle with converters that have been unplugged.

Instructions

1

Raise the vehicle so the tires are at least 24 inches from the ground when raised. Loosen existing exhaust pipes nearest to the catalytic convert so that the exhaust system has at least 1/2 inch of play (4-bolt flanges, exhaust hangers). Mark and cut the exhaust pipe so that there is 3 inches of pipe out the top and 3 inches out the bottom of the catalytic converter. Remove the catalytic converter from the car and take it to a flat work bench or table.

2

Secure the catalytic converter into a 5-inch tabletop vice so that the vice holds the catalytic converter in an upright position with one of the outlets toward the top, and an outlet toward the bottom. The bottom outlet should be placed onto one of the pine board blocks to support the converter when removing the inner mesh of platinum and clogged screen.

3

Insert the pipe into the top outlet of the converter until it is resting on the mesh on the inside of the converter. Rest the second pine board block on top of the pipe that is inserted into the catalytic converter. The pipe and converter should be in a position where it is easy for you to hit the block on top of the pipe that goes into the catalytic converter.

4

Strike the board on top of the pipe that is inserted into the catalytic converter sharply. The best way to remove the platinum mesh inside the catalytic converter is to turn the pipe a little after each strike. You can use the Saws-All to cut notches out of the end of the pipe that goes into the converter, which will act as teeth when struck with a hammer. Be sure that the converter shell is not being damaged when striking the pipe. You need to keep the outer shell of the converter free from holes to keep the exhaust system working without leaks.

5

Remove all the mesh inside of the catalytic converter by driving the pipe through from one end to the other. The mesh will break into little parts that will find their way out the bottom of the converter once the mesh has been entirely broken up. As more and more material is removed from inside the catalytic converter, the converter becomes unplugged and air will once again be able to pass through.

6

Examine the inside of the catalytic converter to be sure that as much of the material is removed as possible. Dislodge and pieces that may come loose later, and attempt to get all the mesh out of the converter before reinstalling. Remove the catalytic converter from the vice and bring back to the vehicle for installation.

7

Weld the unplugged catalytic converter back into the place it was removed, using a car jack or jack stand to get the car in position. Because the exhaust was loosened prior to removing the converter, the pipes can be moved to meet with the old converters inlet and outlet pipes. Weld around the edges of each end of the converter inlet and outlet pipes to reinstall the converter.

The catalytic converter in motor vehicles is an anti-pollution device that chemically converts toxic byproducts of fuel combustion into gases that occur naturally. Some drivers believe that removing the converter will improve performance while others may seek to replace the converter with a section of ordinary exhaust pipe to avoid the cost of replacing a failed converter. Such actions are against Texas state law, and violators face up to a $25,000 fine.

Tampering Illegal

It is illegal in Texas to tamper with properly functioning catalytic converters and other pollution control equipment, says the Texas Commission on Environmental Quality website. Tampering means removing, disabling or otherwise rendering inoperable the pollution control devices installed on a motor vehicle.

Use or Sale Banned

Texas law forbids you to drive a motor vehicle with missing or inoperable pollution control systems. This applies regardless of whether the vehicle is being driven on- or off-road. It is also illegal in Texas to sell, lease or offer a motor vehicle that doesnt have all pollution control systems in proper working order.

Repair Rules

Chapter 114 of the Texas Clean Air Act requires that a missing or failed catalytic converter or other failed pollution control device must be replaced with one specified for that vehicle and which has been certified by the federal Environmental Protection Agency. The repairs must meet the emissions standards established for that vehicle. It is also illegal to add equipment, such as a turbocharger, that wasnt originally certified by the manufacturer for that make and model.

Exemptions

Texas law exempts vehicles and engines used exclusively for auto racing, research and development, or vocational instruction. It also exempts farm vehicles made before 2000, and vehicles or engines being exported from the United States.