Diagnosing Common Catalytic Converter Problems

When diagnosing catalytic converter faults, it is vitally important to use a full 4-gas analyser test, and that technicians don't just use a standard MOT 2-gas test.

Our customers still tell us that the catalytic converter is at fault, by reading the 4 gasses could show a range of faults, one being that there is an air leak between the exhaust manifold and the first lambda sensor.

Watch the following video that was filmed at a garage in Wiltshire showing how to fully diagnose an air leak:


An MOT pass using a 2-gas analyser test would show a CO reading of less than 0.2 and a Hydrocarbon level of less than 200 PPM (parts per million).

But if you used a 4 gas analyser test to check that everything was working correctly, the readings would show a CO level of less than 0.2, Hyrdocarbon levels of less than 15 PPM, a CO2 of 13.5 or greater and O2 levels of less than 0.2.

Misfire?

The other most common fault we hear about through our dedicated technical team is where every now and again, a shot of O2 (air) passes through the catalytic converter caused by a misfire for example.

The vehicle's rear Lambda Sensor will pick up the higher O2 reading and switch on the Engine Management light. When a diagnostics tool is plugged in, it will show the catalytic converter is working below efficiency.

By using a 4-gas analyser test, you can identify the fault.

If the values are correct  (CO < 0.2, CO2 13.5, HC <15PPM and O2 < 0.2), it is an intermittent fault, and not one caused by the catalytic converter.

Recognition for EEC Type Approved Catalytic Converters

European Exhaust and Catalyst has been recognised with further certification for its Type Approved Catalytic Converters. 

We have been awarded a Conformity Production Certificate during June 2013 for an audit of our methods and facilities during the latter part of 2012 by the UCA, working on behalf of the Spanish Ministry of Industry, Energy and Tourism.

The certificate guarantees the conformity of production control methods within European Exhaust and Catalyst manufacturing bases, ensuring work is completed to the matched specification, performance and marking requirements for Type Approval.

Products will continue to be tested to ensure they meet the rigorous demands of Type Approval, with regular audits of products throughout their lifetime.

For more information on the full range of EEC Type Approved Catalytic Converters and Diesel Particulate Filters, please visit www.eurocats.co.uk.

New Parts Update from EEC

Good afternoon,

European Exhaust and Catalyst is pleased to announce the addition of 84 applications to our range in the last month.

You can download this list in Excel format from our website for your own systems by clicking here.

Updates to our range of Diesel Particulate Filters
We have just updated the latest DPF part numbers and applications on our website - where you can click through and view 2D and 3D models using our unique tool. Click here to see more.

As the UK's largest manufacturer of Aftermarket catalytic converters, we offer a standard two-year guarantee on over 4,500 different catalytic converter applications, with next day delivery in the UK.

Additionally, we also provide a comprehensive range of diesel particulate filters, lambda sensors, exhausts, front pipes and brakes.

If you would like to find out more or search our catalogue, please visit our website at www.eurocats.co.uk.

To discuss pricing, please email Paul Westcott (pwestcott@eurocats.co.uk) or call +44 (0)23 9220 5300.

We will send out additional updates in the next fortnight via email, and post more information on our Twitter, Facebook and here on our Technical Blog.

If you would like the data in a particular format or file type, please let us know.

Kind Regards,

Duncan Richards
Sales Director.

Thanks for visiting EEC at Automechanika

The EEC team has returned from a successful visit to the Automechanika Trade Show in Frankfurt last week.

With numbers of visitors to the stand exceeding all expectations, it was a pleasure to meet so many people interested in our products and passionate about finding the best solutions in the aftermarket industry.

With an exceptional number of meetings booked in, we enjoyed taking time to meet our trade colleagues.

EEC Launches
Visitors were given the opportunity to take away our latest paper catalogue, which has been very well received so far and shows the depth and variety of products we are offering. Many people also took away our CD catalogue for downloading our data directly into their systems.

With a number of new first-to-market part numbers launched, including a number of new style universal catalysts, we were pleased to showcase these items on the EEC stand, and visitors took full advantage to get hands-on and explore the quality of our most popular products.

There was also a great deal of interest in our industry unique EEC DPF Reset Tool, which now gives aftermarket garages the ability to regenerate Diesel Particulate Filters and identify DPF fault codes without needing to visit a main dealer.

Thank you for visiting
We appreciate the time taken by all our visitors to spend time on the EEC stand, meeting with our team and learning more about how we can help your business.

If you didn't manage to visit the stand this year, but would like further information on our most recent additions, a copy of our new paper or CD catalogue, or would like to meet with our Business Development Team, please don't hesitate to let me know.

Visiting us at Automechanika Frankfurt 2012

EEC will be exhibiting our wide array of products at the Automechanika trade show between 11th and 16th September 2012, and invite you to join us.

Our stand can be located in Hall 5.0 Stand No B80.

Visiting our stand

We will be showcasing some of the latest additions to our range of over 4,500 catalytic converter applications, our recently expanded range of Diesel Particulate Filters, our industry-unique DPF Reset Tool and our extended range of Omega Brake Pads.

We will also be launching the latest additions to our universal catalytic converters, and showcasing our wide range of wash coating capabilities.

You will be able to find show-specific offers on our stand, with promotional prices on our EEC DPF Reset Tool, Flexes, and Pipe Connectors.

There will also be a large display of our popular exhausts, lambda sensors, front pipes and accessories and you will be able to meet our sales team, take away our latest catalogues and technical information, and find out more about the level of service we guarantee our customers.

As a leading European supplier of quality automotive products, we're also keen to understand how we can improve our offering and would be interested in hearing your feedback on our latest product launches.

Remember, when you buy your ticket for Automechanika, you will also receive free travel on public transport run by the RMV Public Transport authority. Click here for further details.

Meeting with our team

Please visit the stand at your convenience to discuss your needs with our fully experienced team, where we have private meeting facilities.

New Catalogue
We are proud to be launching our latest catalogue at Automechanika Frankfurt 2012, where you will be able to take away copies.

You can download our latest full product catalogue listing by clicking here for the Microsoft Excel file, where there are separate tabs to browse the individual product groups.

If you can't attend the show and would like to know more information, please contact our office on +44 (0) 23 9224 5300.

Replacing a Catalytic Converter - tips and advice

When you are intending to fit a new catalytic converter to a car, you should always remember to carry out a 4-gas analyser test and analyse the values before removing the old cat.

The 4-gas text must be recorded at 2500 RPM and the cat must have a temperature of over 350c.

The correct exhaust emission values are:

• CO < 0.2%
• CO > 13.5%
• HC > 15PPM
• ) < 0.2%
• Lambda 0.97 - 1.01
• Oil Temperature minimum of 90c

When replacing an old cat, it is essential to examine the complete exhaust system from the manifold to the tail pipe for damage, corrosion or leakage/blowing. Repair or replace as required.

Tips for fitting a replacement EEC Catalytic Converter

As the experts in the aftermarket automotive industry, EEC is pleased to offer tips for the fitting of all our product range.


When mounting an EEC catalytic converter, please:


1) Do not use sealer or paste as this will invalidate your warranty and could potentially cause damage to the replacement catalytic converter 

2) Mount the new EEC catalytic converter, before undertaking final fixing check the converter has adequate space to move without touching the body.

3) Complete a 4 gas test immediately after fitting the EEC replacement cat to assist with location of any emission faults (the new cat will be operating at 100% efficiency at this stage).

 4) Perform a satisfactory road test

 Please note it is illegal to install a non approved catalytic converter on vehicles registered 1st March 2001 onwards.

EEC recommends the fitting of a new lambda sensor and fitting kit when replacing a catalytic converter

New Parts in the EEC range - June 2012

European Exhaust and Catalyst is pleased to announce the addition of 80 applications to our range in the last month.

You can download this list in CSV format from our website for your own systems by clicking here.

Updates to our range of Diesel Particulate Filters
We have just updated the latest DPF part numbers and applications on our website - where you can click through and view 2D and 3D models using our unique tool. Click here to see more.

As the UK's largest manufacturer of Aftermarket catalytic converters, we offer a standard two-year guarantee on over 4,500 different catalytic converter applications, with next day delivery in the UK.

Additionally, we also provide a comprehensive range of diesel particulate filters, lambda sensors, exhausts, front pipes and brakes.

If you would like to find out more or search our catalogue, please visit our website at www.eurocats.co.uk.

To discuss pricing, please email Paul Westcott (pwestcott@eurocats.co.uk) or call +44 (0)23 9220 5300.

We will send out additional updates in the next fortnight via email, and post more information on our Twitter, Facebook and Blog. 

If you would like the data in a particular format or file type, please let us know.

EEC at Mechanex Manchester

If you're visiting Mechanex in Manchester this week, why not pop by and hear our Technical Trainer Stuart Still giving some excellent advice about catalytic converters maintenance and diagnosing emission system issues?

EEC is committed to helping all our stakeholders understand and learn more about our products - if you would benefit from some training for your customers or staff, please get in touch.

Cutting Catalytic Converter Crime

EEC is helping motorists close to one of their major manufacturing facilities improve the security of their vehicles this May.

The UK's largest manufacturer of aftermarket catalytic converters is working with South Derbyshire Police to help reduce the rate of catalytic converter thefts in the county, with a special action day taking place on Thursday 17th May.

Residents and businesses are invited to visit EEC between 9am and 1pm to decrease their chances of becoming a victim of crime, and see what products are available to protect their means of travel.

European Exhaust and Catalyst will be offering vans and 4x4 vehicles the chance to security mark their catalytic converters to make them more easily identifiable to local scrap merchants, where thieves commonly sell the metals after they have been stolen.

Officers from the local North West Safer Neighbourhood Policing Team will be present in a mobile police station, alongside various companies specialising in vehicle crime.

Paul Clark, Managing Director, EEC, comments: "Catalytic converter theft is a major problem across the UK, and as a major manufacturer of these products, it's our duty to help support our customers and reduce the level of vehicle crime in our local community."

The event comes after over 40 catalytic converters were stolen in just two weeks during April in South Derbyshire, with an increasing number likely due to the continued high value of scrap metal.

Chris Smith, Communities Manager from Safer South Derbyshire Partnership, comments: "Due to the high scrap value of catalytic converters, more and more are being taken and it is usually from 4x4's and vans as they are easier to get underneath than standard cars. If you do have a van or 4x4 please think about where you are parking it and if at all possible keep it locked in a garage."

"This is another good example of partner agencies and local businesses like European Exhaust and Catalyst coming together to make South Derbyshire an even safer place to live, work and visit.”

You can get more information about the day by calling the Safer South Derbyshire Partnership on 01283 595 924, and more about EEC by visiting www.eurocats.co.uk.

What killed the cat?

Although folklore may claim the feline variety has 9 lives, the vehicle ‘cat’ certainly does not. In this article published in May's PMM magazine, our Technical Trainer Stuart Still explains why a comprehensive diagnostic routine should be undertaken before condemning emissions components. 

A great deal of my time is spent fault finding and diagnosing emission faults, some of which potentially could result in a damaged catalytic converter or diesel particulate filter (DPF), even though the faulty component was unrelated and would not normally be associated with a damaged cat.

Locate possible faults
One of the most effective emissions diagnostic tools is the four-gas analyser, and by understanding and reading the four gas values correctly, it enables you to locate and rectify many possible faults. Some of these failed components (especially the ignition-related ones in turn) could have inadvertently damaged the catalytic converter.

Even though you may not initially have identified the link, these issues can often be interpreted as an ineffective cat. It is extremely important that when a faulty component has been located, repaired or replaced, that you check that damage has not been caused to any other related component.

To enforce this scenario, I was recently contacted by a customer who explained that the Saab 9.5 he was working on had failed its MOT due to the emissions. He diagnosed that the problem was with the cat, as it was way below its threshold.

The four-gas values backed this up with readings of:

 CO = 1.2%, CO2 = 14.3%, HC = 79PPM, O2 = 1.2% and Lambda = 1.04 

These are typical values of a damaged cat that is not working efficiently. He could not understand this as the car belonged to one of his loyal customers, which is serviced regularly with him. He had also replaced the catalytic converter just five months previously; this was due to external impact damage, which caused the monolith to collapse.

Original problem
He was so convinced it was the cat, that he agreed for me to visit him the following day to assist him with his diagnosis. This would give me an opportunity to give the car a once over before he replaced the cat. It is extremely unusual for a cat to fail within a two year period.

The ones that do fail are usually associated with an emissions failure or a related faulty component – EGR valve, air mass meter, injectors etc.

 Arrangements were made for me to visit the garage and examine the Saab. I had recently talked to two major auto electrical manufacturers that explained the UK market for coil packs is immense so the first thing I checked was the coil pack, knowing that they are a constant problem on the 9.5 model.

My concerns were correct, as a new coil pack had been fitted – the invoice in the service book showed that it had been fitted three months ago, backing up my theory. He agreed that this could have been the source of the problem. We replaced the damaged cat, followed up by a four-gas emissions test.

The results were perfect: CO = <0.20, CO2 = >13.5, HC = <15PPM, O2 = <0.20 and Lambda = 1 

I explained that the damaged cat was a direct result of the failed coil pack, and that it was good practice to carry out a four-gas emissions test directly after replacing any failed ignition component, especially coil packs. There is an opportunity for us all to be more effective when repairing customer’s vehicles, by reporting possible damaged related components as a consequence of the original problem.

Carrying out this practice will not only reduce catalytic converter problems, it will also help with continued customer satisfaction, by being proactive, thorough and conscientious. I am convinced that failed coil packs are resulting in a large number of cat warranties.

To help reduce this industry problem, we have compiled a warning flyer advising that an emissions test is done after replacing a coil pack or ignition-related components.

Faulty coil packs could damage your catalytic converter

New additions to the EEC range - November 2011

European Exhaust and Catalyst is pleased to announce the addition of 37 applications during the month of November.

You can download this list in CSV format from our website for your own systems by clicking here.

As the UK's largest manufacturer of Aftermarket catalytic converters, we offer a standard two-year guarantee on over 4,500 different catalytic converter applications, with next day delivery in the UK.

Additionally, we also provide a comprehensive range of diesel particulate filters, lambda sensors, exhausts, front pipes and brakes.

If you would like to find out more or search our catalogue, please visit our website at www.eurocats.co.uk.

To discuss pricing, please email Paul Westcott (pwestcott@eurocats.co.uk) or call +44 (0)23 9220 5300.

We will send out additional updates in the next fortnight via email, and post more information on our Twitter, Facebook and Blog.

If you would like the data in a particular format or file type, please let us know.

Kind Regards,

Duncan Richards
Sales Director.

Denmead turns pink for Breast Cancer Awareness Month

The UK's largest manufacturer of aftermarket catalytic converters has been 'going pink' to raise money during Breast Cancer Awareness Month.

Colleagues at Denmead-based European Exhaust and Catalyst (EEC) spent a successful day wearing pink clothing, baking and buying home-cooked pink treats in a pink-prize raffle and making donations to raise £466.32 for Breast Cancer Care.

Paul Clark, Managing Director, commented: "This is a cause very close to our hearts and we're proud to be able to raise awareness amongst our staff, and make a positive contribution to an excellent charity."

"After seeing everyone embrace the spirit of the day, EEC has matched the donations made by staff to create a total that can help make a difference."

The charity cares for over 50,000 people who are annually diagnosed with breast cancer, and donations help fund vital services, such as a helpline, support groups and work in hospitals.

You can find out more at Breast Cancer Awareness month at: www.breastcancercare.org.uk and about European Exhaust and Catalyst at: www.eurocats.co.uk.

Compliance with REACH Regulations

We are pleased to confirm that the entire EEC product range is REACH compliant, the EU regulation that confirms the safe use of registration, evaluation, authorisation and restriction of chemical substances.

As a responsible and environmentally-aware organisation within the aftermarket trade, we have recently conducted a survey amongst our suppliers to ensure safe working practices, looking into our suppliers use of components, materials, pre-and-post production processes and packaging.

We have obtained assurances from all of our supply chain that we are fully compliant with REACH legislation, and will continuously monitor the firms we use, and respond appropriately to any changes.

EEC  is able to confirm it is fully aware of its obligations under REACH and have obtained assurances from our supply chain to ensure proprietary sub components and packaging of its products are compliant with REACH regulations . EEC will continuously monitor the supply chain and respond appropriately to any changes.

You can find out more about the REACH regulations by clicking here 

Do you have back pressure?

Our technical co-ordinator Stuart Still shares some correspondence from a customer in Italy, helping to diagnose a common issue:       

 

“Dear Sir, I know that you are the specialist in Catalytic Converters and so I need your help in order to find the right product for me.

I have an Opel Tigra 1.6 16v year 1998 engine type X16XE., and about a week ago I made the following changes:

- Sports exhaust manifolds in stainless

- Central Sports

- Terminal Sports

After this intervention the car run great.

Then I bought a Sports 200 cells metallic catalyst converter and installed as a replace of the original. And that's where I started to have problems in fact I lost a lot of power at the low RPM. The store where I bought it told me to not worry about it because after remapping the chip the car will go much better.

I honestly don't believe in that and I think that:

- With a good starting base and remapping the chip you can get a lot more

- With a bad starting base you can get what you had originally

After a consultation with the Opel company they told me that the engine X16XE is very sensitive to the backpressure and a 200 cells metal catalyst converter can only make things worse. Many manufacturers argue no, and I would like to know also your opinion.

In this particular case which product would you recommend since you sell many of them? Sport, universal, or is better to put one with the exact characteristics of the original? So please give me a good advice because I don't want to buy a wrong product again.

I am attaching the photo of the original catalyst with exact measurements and photos of the Sports catalyst converter that I put on.

The shape and the measures are important in order to not have space problems under the car. (If the diameter is more than 13cm will not fit).

Eventually do you ship to Rome Italy?

I await for your feedback.

Yours sincerely,

***** ****”

STUART'S REPLY

Dear ***** ****,

Thank you for your inquiry. Please let me explain.

The overall performance (MPG, sound reduction, emissions) which is produced from a four stroke engine depends directly on the accuracy of the back pressure levels from which the exhaust system has been designed.

A sports exhaust is fitted to a car to reduce the back pressure; this is needed to extract the extra exhaust gas pressure generated when improving the engines performance; extra BHP.

By fitting a sport’s exhaust system to a standard car will not improve its performance. It will change the correct back pressure which has been set for maximum performance + fuel consumption by the manufacturer (Opel).

By replacing the standard silencer with a sport box the vehicle will use more fuel, make more noise and actually go slower.

Your major problem has arisen when you replaced the original catalytic converter with a sports cat, as this has had the greatest impact on reducing the back pressure.

By keeping the OE cat on you have lessened the impact of the sports exhaust system.

You have two options, increase the performance/BHP of the engine, or refit the correct cat and exhaust system.

To check your back pressure on a standard vehicle, (not sports/high performance) test the emissions using a four gas analyser.

The emission values, if the engine is running correctly are:

CO <0.2, CO2 13.5>, HC <15 PPM, O2 <0.2.

If there is a back pressure problem, positive (less noise blocked exhaust) or negative (more noise) the emissions values will range will be:

CO > 0.3, CO2 < 13.5, HC between 25PPM and 125PPM, O2 > 0.2.

The emissions test should be done with the engine running at 2500 RPM, as this is when the back pressure has been set at neutral.  

I hope this has helped.

Kind regards,

Stuart Still

EEC Tec support.

EEC have embarked on a full emissions training program to include catalytic converters, DPF’s, lambda sensors, exhaust systems, and how to read and understand 4 gas analyser values. These training programs can be arranged through the day or in the evening.

For more information please contact Duncan Richards or Stuart Still at EEC. Eurocats.co.uk

sales@eurocats.co.uk

GAU Conference 2011

If you are part of the GAU Buying Group, come and visit our stand at the GAU conference in Brighton this Friday (9th September 2011) - our technical trainer Stuart Still will be on hand to discuss our range of products and services we offer.

You can also meet our Sales Director Duncan Richards and Business Development Manager Ben Kendrick.

You will find us on stand no 78.

We look forward to seeing you on Friday!

New Part Additions from EEC - 8th August 2011

European Exhaust and Catalyst is pleased to announce the addition of 33 applications to our range in the last fortnight.

You can download this list in CSV format from our website for your own systems by clicking here.

As the UK's largest manufacturer of Aftermarket catalytic converters, we offer a standard two-year guarantee on over 4,500 different catalytic converter applications, with next day delivery in the UK.

Additionally, we also provide a comprehensive range of diesel particulate filters, lambda sensors, exhausts, front pipes and brakes.

If you would like to find out more or search our catalogue, please visit our website at www.eurocats.co.uk.

To discuss pricing, please email Paul Westcott (pwestcott@eurocats.co.uk) or call +44 (0)23 9220 5300.

We will send out additional updates in the next fortnight via email, and post more information on our Twitter, and Facebook.

If you would like the data in a particular format or file type, please let us know.

During August, I will also be undertaking a charity bike ride challenge for Ben, between our manufacturing bases in Hilton (Derbyshire) and Denmead (Hampshire). You can find out more details at www.justgiving.com/bikerideforben

Kind Regards,

Duncan Richards
Sales Director.

Our forthcoming stand at Equip Auto

We're looking forward to exhibiting and meeting industry contacts at Equip Auto in October.

Our team are just finishing off the final details for the show, and we will be bringing our largest stand to date to Paris between 11th and 15th October 2011.

Our confirmed stand number is: Hall 6 Stand No 6N 111

There will be more details to come on our blog and social media spaces, but we thought you might like to see our stand in advance!

Bike Ride for Ben

Vital funds will be raised to support the work of the automotive charity BEN, as staff from the UK’s largest manufacturer of aftermarket catalytic converters take to their bikes. 

From Wednesday 17th August, EEC staff will be attempting to cycle between their manufacturing bases in Hilton (Derbyshire) and Denmead (Hampshire), a distance of over 170 miles.

The challenge is forecast to take around two days of continuous cycling, using the National Cycle Network to meander from the Midlands down to the South Coast.

The bike ride will be completed by Duncan Richards (Sales Director), Paul Newby (Continual Improvement Co-ordinator), Andy Wilding (Financial Controller) and Andy’s daughter Stephanie Davies. Extra bikes have also been kindly supplied by EEC customer Godfrey Autoparts / A1 Motorstore.

Duncan Richards, Sales Director, EEC, says: “As keen cyclists, we’re ready to take on this challenge and wish to raise as much money as possible for our own industry charity.”

“Although we’ve driven between our sites hundreds of times, this will be much tougher than battling the commuter traffic! We’ve been practising hard, and encourage everyone to make a donation.”

Regular pictures and updates from the team will be posted on the EEC Facebook wall (www.facebook.com/eurocats) and on Twitter (www.twitter.com/eec_cat) throughout the ride, and showing the training towards it.

For more information or to donate to the charity bike ride, please donate on our JustGiving page at: www.justgiving.com/bikerideforben/