It’s important to have a basic understanding of how catalytic converters operate when servicing them.

An internal combustion engine creates heat energy by igniting a mixture of gasoline and atmospheric
oxygen with a high-voltage spark. Unfortunately, a residual quantity of hydrocarbons (HC), carbon
monoxide (CO), and nitrogen oxides (NOX) are left over after combustion. Consequently, a catalytic
converter uses precious metals like platinum as a catalyst to convert harmful pollutants like HC, CO and
NOX into harmless gases like oxygen (O2), carbon dioxide (CO2) and water (H2O). Since a catalyst will
accelerate a chemical reaction without being consumed by the process itself, the catalytic converter will
theoretically last forever. In reality, catalytic converters eventually succumb to contaminants from
coolant and engine oil additives and heat stress.

Converter types

“Direct-fit” catalytic converters are of three basic types: two-way, three-way and three-way plus
oxidation converters. Two-way “oxidation” converters are used up to 1980 and are designed to
eliminate hydrocarbons (HC) and carbon monoxide (CO). Three-way converters are designed to
eliminate nitrogen oxides (NOX) as well. A Three-way plus or “dual-bed” converter allows atmospheric
air to be injected between the three-way catalyst and an extra oxidation bed to further clean the engine
exhaust. The precious metals used as catalysts are distributed in molecular form over a rough-surfaced
ceramic wash coat covering the metallic honeycomb substrate. The effectiveness of the converter is
basically determined by the amount of precious metals present on the honeycomb substrate.
Consequently, it’s very important for supplier and technician alike to meet EPA requirements by
selecting the correct catalytic converter for the application.

The Catalyst Monitor

Only after the engine is started and driven, does the catalyst monitor run. Basically, the engine control
module (ECM) uses a mathematical algorithm to compare the electrical activity of the upstream oxygen
sensor (before the converter) with that of the downstream oxygen sensor. When the electrical activity
of the upstream and downstream oxygen sensors doesn’t meet programmed parameters, a diagnostic
trouble code (DTC) P0420 and/or P0430 is stored in the ECM’s diagnostic memory and the orange
“Check Engine” warning light is illuminated.
Because the catalyst monitor is mathematically-based, attempting to diagnose a converter by comparing
inlet and outlet temperatures or by using an exhaust gas analyzer will not yield valid test results. When a
P420/430 diagnostic trouble code (DTC) is present, the professional technician should check for related
ECM calibration update bulletins before replacing a catalytic converter. In many cases, reprogramming
the PCM might solve a stubborn P420/430 DTC issue.

Causes of Catalyst Failure

An ignition system misfire is the most common cause of catastrophic converter failure. The catalytic
converter overheats because combustion takes place in the converter rather than the engine when a
misfire occurs. When the converter exceeds an operating temperature of about 1,300 degrees F, the
converter substrate begins to melt and cause exhaust restriction. Common failures also include a
catalyst suffering from an external impact or being contaminated by coolant from leaking cylinder head
gaskets.

When to Sell Catalytic Converters

The auto manufacturer’s original equipment (OE) catalytic converters are initially covered by an EPA-
mandated 8-year, 80,000-mile warranty. Only if the original is missing, fails a state or local emissions
inspection program, or is plugged, leaking, or has sustained physical damage can a new aftermarket
catalytic converter can be installed. Most vehicles require catalytic converter replacements when an
illuminated “Check Engine” warning light indicates a converter failure or if the engine itself has failed an
exhaust emissions test. To pass an exhaust emissions test, the converter must meet the exact
configuration and capacity as specified by the original equipment (OE) manufacturer. Due to adopting
more stringent emissions standards, many other states are now requiring catalytic converters that meet
California specifications. When selling any catalytic converter, remember to fill out the paperwork as
required by state and local agencies.