Assembly instructions;

Catalysts

The catalytic converter should last at least 100,000 km. If this is not the case, it is mainly due to the following:

• External damage
• Clogging or contamination
• Oil/Antifreeze contamination
• Overheating

If the above problems occur, the new catalytic converter will not be covered by the warranty! Before installing a new catalytic converter, first fix the cause of the problem! If this is not done, the new catalyst will quickly stop working. Read more about this under more information (catalysts) .

More information (catalysts)

External damage

The ceramic material in the catalyst is made of light, thin-walled, and brittle material. The insulation layer holds the material in place and provides some protection against external damage. However, cracks can occur in the ceramic material due to factors such as speed bumps and rocks on the road. In addition, poor installation, loose exhaust mounting paste, and broken exhaust system can also cause the ceramic material to break and/or crack.

Clogged or dirty

Clogging and/or fouling of catalytic converters can occur due to the use of incorrect fuel. Using leaded or lead-substitute fuels clogs the ceramic material and stops it from working. This also applies to fuel additives that are not suitable for systems with catalysts. When oil or antifreeze enters the exhaust system, it can block the air passage due to a heavy layer of soot depositing against the ceramic plates in the catalytic converter. This causes the interior to become clogged and airflow to be restricted. This can cause loss of power and cause the engine to overheat. This can cause leaking seals, wear of piston rings or damage to other engine parts.

Overheating

When excess fuel enters the exhaust system, it will burn when it reaches the catalytic converter. This can result in overheating and burning of precious metals. The catalyst loses its effectiveness and in severe cases the ceramic part melts and the catalyst becomes clogged. Possible causes include incorrect fuel ratio, incorrect engine settings, worn spark plugs, faulty lambda sensors or malfunctions.

Sound production

Despite its sound-dampening properties, the catalytic converter should not be labeled as a sound absorber. Rattling and/or whistling noises may occur when there is excessive fuel burning through the insulating protective layer in the catalytic converter.

A catalyst can only function properly in a combustion process that operates according to factory specifications. If not handled properly, the catalyst can be completely lost (fused monolith). All possible causes must be resolved before a new catalytic converter is installed.

Minimum checklist:

• Check and/or replace oil filter
• Check and/or replace air filter
• Check and/or replace spark plug
• Check engine management
• Check the turbo
• Check LPG installation (if applicable)
• Check oil consumption
• Check coolant consumption
• Check the cylinder head gasket for leaks
• Check the exhaust gas mixture
• Check the quality and capacity of the (pre)catalyst
• Check all sensors (lambda sensors)
• Check EGR valves and system

You should also test the following:

• Injectors
• Busy
• Starter motor and battery
• Emission test

Do not use liquid gaskets on the front of the catalytic converter and always make sure the correct oil is used. It is strongly recommended that the oil be changed when replacing the catalytic converter.

Only when all conditions of the minimum checklist are met can the catalyst do its job properly.