Check Engine Light cam on last night.

Had the code scanned. It's the... P0422: Catalyst System Efficiency Below Threshold (Bank 1)... meaning my catalytic converter is the problem.

I just changed the O2 sensors (went with OEM direct fit for both) 2 weeks ago. So I know those are good (at least it's safe to assume).

Reading the archived posts and other internet sources, I've determined what it could be, in this order....

1. O2 Sensors failure
2. Vacuum Leaks
3. Mass Air Flow (MAF) sensor failure
4. Coolant Temp Sensor??? (Someone mentioned this... unsure what or where it is)
5. Exhaust Leaks
6. Retarded Spark Plug timing
7. Air Intake Leaks
8. Bad Catalytic Converter

Figured i'd swap out the MAF (since I have a spare) and look around for any vacuum leaks, intake leaks, anything obviously not-right. I'll have a mechanic look for exhaust leaks for me (shouldn't cost much to do that). But other than that...

Thoughts?

 

The last piece... a new catalytic converter... is costly!

Bob's Volvo Service in Denver, CO... qoutes $1200 for an OEM cat, installed ($996 for just the new cat)

Foreign Car Repair in Thornton, CO... qoutes $500 for an aftermarket cat, installed.

But aftermarket... i'd like to avoid... I hate nothing more in this life than the CEL.... and if that thing were to come on again because of an aftermarket cat... i'd be pissed.

 

If you had exhaust leaks, it would mean that the cat and the O2 sensor would actually be seeing smaller levels of exhaust gases - which would make me think it wouldn't throw a code.

"Catalyst System Efficiency Below Threshold" means the cat isn't efficient anymore; in other words, failing to do its job. The code tells me that the O2 sensor is picking up too many emissions that the cat is supposed to remove.

Take a rubber mallet and gently smack the cat a few times. If you hear anything rattling around inside of it, odds are good that it’s falling apart and is the (damn expensive) problem.

 

Yep, took it to a little shop for a free exhaust inspection.

Sure enough, that's exactly what they show me... bang on the cat a bit and you can hear some rattling. Meaning that platinum is breaking down and I need a new cat.

Anyone got a cat from a "parts car" they can sell me?

The funny thing about catalytic converters... they won't sell them at junk yards and they can't be "rebuilt"... that federal emissions law prevents that. But... if I were to find one, it's pretty much a "cut off" and "weld on" job I think.

 

Anyone know what kind of cat I should be looking for? Ideally i'm thinking I should look for a '95 Volvo 850... but there are guys on here selling parted out cars before they head to the junkyard... thinkin' i might be able to snag a cat before they toss 'em (plus, i'll pay for it... so cha-ching!) ;-)

 

I believe it's against the law to sell a used cat - but I'm not sure if its illegal to be found giving one away

 

I don't mind that it's against the law... looking for a 3rd party that also doesn't care. Afterall, i'm trying to REPAIR this so that I have a working cat. Otherwise, i'll register my car in another county that doesn't require emissions and just drive around with my CEL on (but also with $1200 still in my wallet).

 

So i'm looking around online for a new cat... someone's got to sell the OEM part for less... and if I get one, maybe I can install the whole thing myself?

But I can't seem to figure out what's what... no one really selling something called an "OEM 1995 Volvo 850 Catalytic Converter"... anyone know what brand I should be looking for?

 

Just popped this P0422 code. I did notice ealier today the car didn't seem to accellerate as agressive as usual. Do these things just go out all the sudden?

 

Yeah, sometimes. When the material inside breaks down, it just starts to block the proper exhaust flow and can clog the pipes. Give it a 'love tap' and see if there's any rattle.

 

Be careful how hard you hit it as you may cause it to rattle when it wasn't broken before you started to bang on it.
usually hitting it with your hand will cause a fractured cat to rattle if there is anything in there loose. If you use a hammer it's likely you'll hear a rattle because you used the hammer !!

 

The best way is to get a thermal temp sensor. My friend who has a VW garage has one and we placed the volvo on the hoist an guess what, the temp at the front of my cat was over 100 deg hotter than at the rear, blocked cat.

I too am working the CAT decision before Mar 2013 when my tags renew.

IPD does sell a complete stainless steel system from the header to the tailpipe for about $995 (includes the 49 state CAT).
Turbo Back Sport Exhaust Kit - Straight Flange
they also have the angle flange same price.

Has anyone installed this system from IPD?

 

We don't have inspections so I'm up in the air as to what I'll do if my cat is bad. I reset my code 462 miles ago and it hasn't come back.

 

I had my cat done recently, cost me $450 and it was a cat to suit a ford falcon. I was looking at $900 for the volvo one here, no issues with check engine lights or anything else, runs just fine in my car.

 

I have the OBX system and it's really nice.

 

Another 430 miles on it and still no CEL. Hopefully it was a system hick-up.

 

I believe that code takes a while to set.

We don't have emissions here either. My cars' TWCs may or may not have a non-stock weld bead down their centers.

 

Getting a "universal" cat shouldn't be a problem (unless it's Calif, there I don't know) all the auto parts stores sell them and they are certified for 49 state compliance so passing an emissions test shouldn't be a problem. They are universal in that they will legally clean the exhaust of a certain range of displacement engines and don't just bolt in. They are cheaper because you have to "fit" them into the location instead of the same converter which would have the same inlet or exhaust piping and or flanges that would allow you to just bolt it or clamp it into place.
I looked up mine on line and if I had a stock exhaust I could use a new Magnaflow part # 91006 for $75.99
The direct fit one would be a Walker part # 55415 at $498.

Picture one, universal. Picture two, direct fit.

 

The Walker looks to have both O2 bungs which is nice but for the MagnaFlow, the OEM cat holds both O2 sensors so you'll have to make sure you have the shop add those to your pipes, adding to your 'out the door' cost.

 

And it depends on where you cut the pipe to section in the universal. You can get lucky and end up using the original locations since the universals are usually shorter in "body" length than the original.

But if you need to replace the bung they are easily available and it might be a good time to add an extra one for a wideband O2 sensor to run an air fuel mixture gauge !!