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Technical InformationIntroduction Of Catalytic ConvertersCatalytic converters on motor vehicles were introduced in the U.K. in the early 1990’s to cut down on air pollution caused by exhaust fumes. It was hoped that the use of catalytic converters on cars would improve the overall air quality, especially in big cities where smog can be a problem. Catalytic converters also have other environmental and health benefits. They cut down the amount of the poisonous gas carbon monoxide leaving the exhaust pipe. Catalytic converters also cut down on the amount of nitrous oxides that enter the atmosphere. Nitrous oxides are the primary cause of smog and acid rain. It should be remembered that while catalytic converters filter out the most harmful substances they still release gases that are harmful to the atmosphere, like carbon dioxide.
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How Does It Work?The catalytic converter usually consists of a honeycomb structured ceramic monolith, which is surrounded by matting. The matting holds the monolith securely in place and provides a cushion against road shock and vibration. This is all encased in a steel shell to provide further protection. Another option is a steel monolith, which is more durable. The steel monolith we supply has a texture similar to cotton wool. The catalytic converter is situated in the exhaust pipe, usually close to the manifold. This is because the catalyst needs to reach a certain temperature before it starts to operate properly, so the closer it is to the engine the quicker it reaches operating temperature.
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CO, HC and NO enter the catalystCarbon Monoxide (CO) |
CO2, H2O and N leave the catalyst as fumesCarbon Dioxide (CO2) |
The monolith is coated with platinum, palladium and rhodium. These substances cause a chemical reaction to take place as the exhaust fumes pass through the monolith. The carbon monoxide is converted to carbon dioxide, the hydrocarbons are converted into water and carbon dioxide, and nitrous oxide is converted into nitrogen.
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Advice For FittersCatalytic Converters can be extremely difficult to fit. The following advice may be of use when trying to fit your catalytic converter: 1. Don’t attempt to fit a catalytic converter unless you have experience in doing so. Catalytic converters are very expensive items and any mistake could damage it. 2. Never use exhaust paste in front of the catalytic converter. 3. Don’t hit the catalytic converter with a mallet or hammer to try and force it into place. Doing so may fracture the monolith and invalidate the warranty. 4. Use new fittings, such as gaskets or nuts and bolts wherever possible. 5. Always offer the cat to the car to see if it will fit. If you believe the catalytic converter would have to be altered to fit contact your point of purchase. You may have the wrong catalytic converter for your car. Any alterations made without our authorisation will invalidate the warranty.
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Caring for the Cat ConverterThere are several things you can do to ensure your CAT has a long and healthy life: 1. When fitting the catalytic converter don’t use exhaust paste in front of the cat. When the exhaust paste hardens it can break off in chunks and destroy the monolith. 2. Always use the correct fuel for your car. 3. Never use a fuel additive without first reading the instructions to find out if it is suitable for use with a catalytic converter. If in doubt, consult the manufacturer of the additive. 4. Never attempt to bump or tow start your car. This causes unburned fuel to be injected into the cat, which makes the monolith overheat and melt. 5. Never tow anything that is too heavy for your vehicle to cope with. For example, an overloaded caravan will actually push a car along when it travels downhill. This sends unburned fuel into the exhaust system and can cause the monolith to melt down. 6. Have your car regularly serviced to your car manufacturers specifications. In particular make sure the engine is running properly. A poorly tuned engine can cause the monolith to break down or become covered in soot, which stops it working correctly. 7. Take care when driving through deep puddles, fords, or parking when there has been heavy snow. The cat operates at an extremely high temperature, and when it comes into contact with water or snow it cools down rapidly. The steel shell cools more rapidly than the monolith, and in extreme circumstances the monolith can be crushed as the steel shell contracts. 8. Don’t park your car over long grass or anything similar. As the cat operates at such a high temperature it can actually set the grass on fire! 9. Drive slowly over speed bumps or very bumpy roads to reduce the chance of the exhaust system being grounded. This could cause impact damage to the cat.
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Warranty Information.Although every effort is made to ensure our catalytic converters will not fail, sometimes a problem with the vehicle will cause them to break down. The following problems are NOT covered by our guarantee: Road Damage Plugged Or Contaminated. Oil Fouled Melted/Broken Substrate The use of exhaust paste before the cat can also cause the monolith to break. When the exhaust paste has hardened small pellets can break away and shoot into the cat. The monolith will gradually be destroyed by these pellets and break down. The cat can also be destroyed by excessive engine vibration. A rapid change of temperature can also break the monolith. (See number 7 in “Caring for your Catalytic Converter”) The monolith can be melted when unburned fuel is injected into the cat. This can be caused by the car being tow or bump started, or if the car’s engine requires several turns before firing. More information on the causes of melting monoliths can be found in the section on “Overheating”. Overheating Oxygen Sensor Fuel Injection Systems Map Sensors Carburettor Systems Canister Purge Valve Control Noise None of the described faults are covered by the guarantee and any parts returned with a fault as described will not be credited.
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