* * * * * * * * * *CATALYTIC CONVERTER FAILURE * * * * * * * * * *
Catalytic converter failures typically fall into one of four categories:
1. Thermal failure (overheating)
2. Plugged substrate
3. Thermal shock
4. Physical damage
Thermal failure is most often caused when excessive raw fuel comes into contact with
the catalyst, and "burns" in the converter instead of in the engine. The high quantity of
fuel generates temperatures well in excess of the capacity of the converter, causing meltdown
of the ceramic monolith. The melted ceramic could block the exhaust path, leading to a
significant loss of engine power. Visible symptoms include heat-related discoloration of
the converter shell. Potential causes of thermal failure include: misfire, malfunctioning
oxygen sensor, fuel delivery issue, improper choke setting/operation, and ECU malfunction.
A plugged or contaminated substrate can be the result of an overly rich air/fuel mixture,
radiator sealant, and oil or antifreeze entering the exhaust flow. The resultant carbon
deposits restrict the operation - and ultimately the flow characteristics - of the converter
by coating the unit's reactive surface. This degrades the converter's ability to perform its
chemical conversion process, leading to potentially illegal levels of HC, CO, and NOx.
Root causes of this problem are a malfunctioning O2 sensor, plugged or inoperable fuel injectors,
piston blow-by, leaking head gasket, broken or frozen choke or carburetor float, excessive
cranking time, and repeated incidences of running out of gas.
Thermal shock occurs when a fully heated converter suddenly is "cold-quenched," such
as coming into contact with snow or ice. This leads to sudden contraction of the converter
housing, which can cause cracks and disintegration of the ceramic substrate. Symptoms
include a "rattling'' sound when the converter is tapped with a fist or mallet (monolith-type
converters only).
Physical damage, caused by running over road debris, collisions and other impacts, is
usually easy to diagnose. This type of damage can break up the ceramic substrate or
cause restriction that changes the flow characteristics of the converter
or impacts the efficiency of the catalyst.
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