Chapter 29

OBJECTIVES
After studying Chapter 29, the reader will be able to:

1. Prepare for ASE Engine Performance (A8)
certification test content area “D” (Emission
Control Systems).
2. Describe the purpose and function of the catalytic
converter.
3. Discuss how the catalytic converter is tested under
OBD-II regulations.
4. Explain the method for diagnosing and testing the
catalytic converter.
Automotive Fuel and Emissions Control Systems, 2/e © 2009 Pearson Higher Education, Inc.
By James D. Halderman and Jim Linder Pearson Prentice Hall - Upper Saddle River, NJ 07458
CATALYTIC CONVERTERS
• A catalytic converter is an
after-treatment device used
to reduce exhaust
emissions outside of the
engine.
• This device is installed in
the exhaust system
between the exhaust
manifold and the muffler,
and usually is positioned FIGURE 29-1 Typical catalytic converter.
The small tube into the side of the
beneath the passenger converter comes from the air pump. The
compartment. additional air from the air pump helps
oxidize the exhaust into harmless H2O and
CO2.
CERAMIC MONOLITH CATALYTIC CONVERTER
FIGURE 29-2 A typical catalytic converter with a monolithic substrate.
Catalytic Converter Operation
• The converter contains small amounts of rhodium,
palladium, and platinum.
• These elements act as catalysts.
– A catalyst is an element that starts a chemical reaction
without becoming a part of, or being consumed in, the
process.
– In a three-way catalytic converter (TWC), three exhaust
emissions (NOX, HC, and CO) are converted to carbon
dioxide (CO2) and water (H2O).
FIGURE 29-3 The three-way catalytic converter first separates the NOX into
nitrogen and oxygen and then converts the HC and CO into harmless water (H2O)
and carbon dioxide (CO2).
FIGURE 29-4 A cutaway of three-way catalytic converter showing the air tube in
the center of the reducing and oxidizing section of the converter. Note the small
holes in the tube to distribute air from the AIR pump to the oxidizing rear section
of the converter.
Converter Light-Off
• The catalytic converter does not work when cold
and it must be heated to its light-off temperature of
close to 500°F (260°C) before it starts working at
50% effectiveness.
Converter Usage
• A catalytic converter must be located as close as
possible to the exhaust manifold to work effectively.
• The farther back the converter is positioned in the
exhaust system, the more gases cool before they
reach the converter.
CATALYTIC CONVERTER WARM-UP TEST
• The PCM determines if the catalytic converter is

ready for testing based on the following conditions,
which may vary by vehicle make, model, and year.
– Closed-loop status achieved
– IAT sensor temperature higher than 32°F (0°C)
– ECT sensor temperature higher than 165°F (18°C)
– MAF sensor input from 15 to 32 g/sec
– Engine load less than 65% and steady
– Engine speed less than 4000 RPM
– All of the above conditions met for at least four minutes
OBD-II CATALYTIC CONVERTER PERFORMANCE
• With OBD-II equipped

vehicles, catalytic converter
performance is monitored
by a heated oxygen
(HO2S) sensor both before
and after the converter.
FIGURE 29-5 The OBD-II catalytic

converter monitor compares the signals
of the upstream and downstream O2Ss
to determine converter efficiency.
OBD-II CATALYTIC CONVERTER PERFORMANCE
FIGURE 29-6 The waveform of an O2S downstream from a

properly functioning converter shows little, if any, activity.
CONVERTER DAMAGING CONDITIONS
• The three main causes of

premature converter failure
are as follows:
– Contamination.
– Excessive temperatures.
– Improper air-fuel mixtures.
FIGURE 29-7 The highest catalytic

converter efficiency occurs when the air-
fuel mixture is about 14.7:1.
DIAGNOSING CATALYTIC CONVERTERS
The Tap Test
• The simple tap test involves
tapping (not pounding) on
the catalytic converter
using a rubber mallet.
• If the substrate inside the
converter is broken, the
converter will rattle when
hit.
• If the converter rattles, a
replacement converter is
FIGURE 29-8 A catalytic converter that rattles
required. when tapped was removed and the substrate, or
what was left of it, fell out. This converter has to
be replaced and the root cause of why it failed
found and corrected.
DIAGNOSING CATALYTIC CONVERTERS
Testing Back Pressure with a Vacuum Gauge
• A vacuum gauge can be used to measure manifold
vacuum at a high idle (2000 to 2500 RPM).
• If the exhaust system is restricted, pressure
increases in the exhaust system.
• This pressure is called back pressure.
• Manifold vacuum will drop gradually if the engine is
kept at a constant speed if the exhaust is restricted.
TESTING BACK PRESSURE WITH A PRESSURE
GAUGE
• Exhaust system back pressure can be measured directly by
installing a pressure gauge in an exhaust opening.
• This can be accomplished in one of the following ways.
– To test an oxygen sensor, remove the inside of an old, discarded
oxygen sensor and thread in an adapter to convert it to a vacuum or
pressure gauge.
– To test an exhaust gas recirculation (EGR) valve, remove the EGR
valve and fabricate a plate.
– To test an air injection reaction (AIR) check valve, remove the check
valve from the exhaust tubes leading to the exhaust manifold.
• Use a rubber cone with a tube inside to seal against the exhaust tube.
• Connect the tube to a pressure gauge.
GAUGE
FIGURE 29-9 A back pressure tool can be easily made by attaching a short
section of brake line to the shell of an old oxygen sensor. Braze or epoxy the
tube to the shell
GAUGE
FIGURE 29-10 A photo of a partially melted catalytic converter that tested

okay at idle but had excessive back pressure at idle speeds.
TESTING BACK PRESSURE WITH A PRESSURE GAUGE
Testing a Catalytic Converter for Temperature Rise
• A properly working catalytic converter should be
able to reduce NOX exhaust emissions into nitrogen
(N) and oxygen (O2) and oxidize unburned
hydrocarbon (HC) and carbon monoxide (CO) into
harmless carbon dioxide (CO2) and water vapor
(H2O).
Testing a Catalytic Converter for Temperature Rise
FIGURE 29-11 The temperature of the

outlet should be at least 10% hotter
than the temperature of the inlet. This
converter is very efficient. The inlet
temperature is 450°F.Ten percent of
450° is 45° (45°450°495°). In
other words, the outlet temperature
should be at least 495°F for the
converter to be considered okay. In this
case, the outlet temperature of 525°F
is more than the minimum 10%
increase in temperature. If the converter
is not working at all, the inlet
temperature will be hotter than the
outlet temperature.
Catalytic Converter Efficiency Tests
• The efficiency of a catalytic converter can be
determined using an exhaust gas analyzer.
– Oxygen level test.
• If O2 is zero, go to the snap throttle test.
• If O2 is greater than zero, check the CO level.
• If CO is greater than zero, the converter is not functioning correctly.
– Snap-throttle test.
• The O2 reading should not exceed 1.2%; if it does, the converter is not
working.
• If the O2 rises to 1.2%, the converter may have low efficiency.
• If the O2% remains below 1.2%, then the converter is okay.
OBD-II CATALYTIC CONVERTER MONITOR
• The catalytic converter monitor of OBD-II uses an

upstream and downstream HO2S to test catalytic
efficiency.
– When the engine combusts a lean air-fuel mixture, higher
amounts of oxygen flow through the exhaust into the
converter.
– The catalyst materials absorb this oxygen for the
oxidation process, thereby removing it from the exhaust
stream.
CATALYTIC CONVERTER REPLACEMENT
GUIDELINES
• Because a catalytic converter is a major exhaust gas
emission control device, the Environmental Protection
Agency (EPA) has the following strict guidelines for its
replacement.
– If a converter is replaced on a vehicle with less than 80,000 mi/eight
years, depending on the year of the vehicle, an original-equipment
catalytic converter must be used as a replacement.
– The replacement converter must be of the same design as the
original. If the original had an air pump fitting, so must the
replacement.
– The old converter must be kept for possible inspection by the
authorities for 60 days.
– A form must be completed and signed by both the vehicle owner and
a representative from the service facility.
CATALYTIC CONVERTERRELATED DIAGNOSTIC
TROUBLE CODE
CATALYTIC CONVERTER OPERATION
SUMMARY
1. A catalytic converter is an aftertreatment device

that reduces exhaust emissions outside of the
engine.
2. The honeycomb shape of the catalytic converter is
constructed of a ceramic material about 0.006 in.
thick with small square openings.
3. A catalyst is an element that starts a chemical
reaction but is not consumed in the process.
4. The catalyst materials used in a catalytic converter
include rhodium, palladium, and platinum.
SUMMARY
5. A catalytic converter has to be over 500°F

(260°C) before it starts to become effective, and
is therefore mounted as close as possible to the
exhaust parts of the engine.
6. The OBD-II system monitor compares the relative
activity of a rear oxygen sensor to the precatalytic
oxygen sensor to determine catalytic converter
efficiency.
7. Catalytic converters can be tested for restriction
and for efficiency.
REVIEW QUESTIONS
1. What are the three most commonly used catalysts

used in a catalytic converter?
2. How does a catalytic converter reduce NOX to
nitrogen and oxygen?
3. Why must a catalytic converter be mounted close
to the exhaust ports of the engine?
4. How does the computer monitor catalytic converter
performance?
5. What tests can be performed by a service
technician to test the catalytic converter?
CHAPTER QUIZ
1. What is applied to the ceramic substrate to make

the surface porous?
a) Honeycomb filler
b) Washcoat
c) Aluminum
d) Cerium
CHAPTER QUIZ
1. What is applied to the ceramic substrate to make

the surface porous?
a) Honeycomb filler
b) Washcoat
c) Aluminum
d) Cerium
CHAPTER QUIZ
2. Two technicians are discussing catalytic

converters. Technician A says that the exhaust
mixture must be at stoictiometric for the best
efficiency. Technician B says that the air-fuel
mixture must be leaner than 14.7:1 for best
performance from a three-way catalytic converter.
Which technician is correct?
a) Technician A only
b) Technician B only
c) Both Technicians A and B
d) Neither Technician A nor B
CHAPTER QUIZ
2. Two technicians are discussing catalytic

converters. Technician A says that the exhaust
mixture must be at stoictiometric for the best
efficiency. Technician B says that the air-fuel
mixture must be leaner than 14.7:1 for best
performance from a three-way catalytic converter.
Which technician is correct?
CHAPTER QUIZ
3. A catalytic converter has to be at least how hot

before it starts to work?
a) 500°F (260°C)
b) 1,000°F (540°C)
c) 1,500°F (815°C)
d) 2,000°F (1,100°C)
CHAPTER QUIZ
3. A catalytic converter has to be at least how hot

before it starts to work?
a) 500°F (260°C)
b) 1,000°F (540°C)
c) 1,500°F (815°C)
d) 2,000°F (1,100°C)
CHAPTER QUIZ
4. What two primary sensors does the PCM use to

check the catalytic converter?
a) Catalytic converter temperature sensor and rear oxygen
sensor
b) Precat and postcat oxygen sensor
c) Precat oxygen sensor and MAF
d) MAP and TP
CHAPTER QUIZ
4. What two primary sensors does the PCM use to

check the catalytic converter?
a) Catalytic converter temperature sensor and rear oxygen
sensor
b) Precat and postcat oxygen sensor
c) Precat oxygen sensor and MAF
d) MAP and TP
CHAPTER QUIZ
5. A catalytic converter can be harmed by _____.

a) Excessive engine oil
b) Antifreeze
c) Sulfur from poor-quality fuel
d) Any of the above
CHAPTER QUIZ
5. A catalytic converter can be harmed by _____.

a) Excessive engine oil
b) Antifreeze
c) Sulfur from poor-quality fuel
d) Any of the above
CHAPTER QUIZ
6. Two technicians are discussing testing a catalytic

converter. Technician A says that a vacuum gauge
can be used and observed to see if the vacuum
drops with the engine at idle for 30 seconds.
Technician B says that a pressure gauge can be
used to check for back pressure. Which technician
is correct?
CHAPTER QUIZ
6. Two technicians are discussing testing a catalytic

converter. Technician A says that a vacuum gauge
can be used and observed to see if the vacuum
drops with the engine at idle for 30 seconds.
Technician B says that a pressure gauge can be
used to check for back pressure. Which technician
is correct?
CHAPTER QUIZ
7. A catalytic converter is being tested with an

infrared pyrometer. Which is an acceptable (good
converter) result?
a) The inlet should be hotter than the outlet by 10%.
b) The outlet should be hotter than the inlet by 10%.
c) Both the inlet and the outlet should be the same
temperature after the converter reaches operating
temperature.
d) The temperature of a catalytic converter is the best test
to perform to locate a restricted (clogged) unit.
CHAPTER QUIZ
7. A catalytic converter is being tested with an

infrared pyrometer. Which is an acceptable (good
converter) result?
a) The inlet should be hotter than the outlet by 10%.
b) The outlet should be hotter than the inlet by 10%.
c) Both the inlet and the outlet should be the same
temperature after the converter reaches operating
temperature.
d) The temperature of a catalytic converter is the best test
to perform to locate a restricted (clogged) unit.
CHAPTER QUIZ
8. Which exhaust gas reading indicates a good

catalytic converter?
a) O2 is zero
b) CO is zero
c) Both a and b
d) Neither a nor b
CHAPTER QUIZ
8. Which exhaust gas reading indicates a good

catalytic converter?
a) O2 is zero
b) CO is zero
c) Both a and b
d) Neither a nor b
CHAPTER QUIZ
9. A P0422 (catalytic converter efficiency failure) is

set. What is a possible cause?
a) Engine mechanical fault
b) Exhaust leak
c) Fuel contamination
d) Any of the above
CHAPTER QUIZ
9. A P0422 (catalytic converter efficiency failure) is

set. What is a possible cause?
a) Engine mechanical fault
b) Exhaust leak
c) Fuel contamination
d) Any of the above
CHAPTER QUIZ
10. Technician A says that the catalytic converter is

warranted for eight years or 80,000 mi, whichever
comes first. Technician B says that after replacing
the catalytic converter, the old converter must be
kept for possible inspection for 60 days. Which
technician is correct?
CHAPTER QUIZ
10. Technician A says that the catalytic converter is

warranted for eight years or 80,000 mi, whichever
comes first. Technician B says that after replacing
the catalytic converter, the old converter must be
kept for possible inspection for 60 days. Which
technician is correct?

Chapter 29

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Chapter 29

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OBJECTIVES

After studying Chapter 29, the reader will be able to:

FIGURE 29-2 A typical catalytic converter with a monolithic substrate.

• The PCM determines if the catalytic converter is

• With OBD-II equipped

FIGURE 29-5 The OBD-II catalytic

FIGURE 29-6 The waveform of an O2S downstream from a

• The three main causes of

FIGURE 29-7 The highest catalytic

FIGURE 29-10 A photo of a partially melted catalytic converter that tested

FIGURE 29-11 The temperature of the

• The catalytic converter monitor of OBD-II uses an

1. A catalytic converter is an aftertreatment device

5. A catalytic converter has to be over 500°F

1. What are the three most commonly used catalysts

1. What is applied to the ceramic substrate to make

1. What is applied to the ceramic substrate to make

2. Two technicians are discussing catalytic

2. Two technicians are discussing catalytic

3. A catalytic converter has to be at least how hot

3. A catalytic converter has to be at least how hot

4. What two primary sensors does the PCM use to

4. What two primary sensors does the PCM use to

5. A catalytic converter can be harmed by _____.

5. A catalytic converter can be harmed by _____.

6. Two technicians are discussing testing a catalytic

6. Two technicians are discussing testing a catalytic

7. A catalytic converter is being tested with an

7. A catalytic converter is being tested with an

8. Which exhaust gas reading indicates a good

8. Which exhaust gas reading indicates a good

9. A P0422 (catalytic converter efficiency failure) is

9. A P0422 (catalytic converter efficiency failure) is

10. Technician A says that the catalytic converter is

10. Technician A says that the catalytic converter is

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