S40 Catalytic Converter
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S40 Catalytic Converter
2002, S40, 180k, 4dr, loaded, 1.9L with a turbo.
I recently had the following work done in December:
https://volvoforums.com/forum/volvo-...-repair-81413/
The CEL has been turning on and off randomly recently. The car appeared to be running good this morning so I punched the gas to get the turbo to initialize. I had a ton of backfire and rough running. CEL FLASHED for about 30 seconds and then turned off.
Took it to O'Reilly and had the following codes returned...
P0420: Catalyst System Efficiency Below Threshold Bank 1
P0456: EVAP System Leak Detected (very small leak)
P0302: Cylinder 2 Misfire
It can sometimes idle roughly (backfires) when it is first started up in the morning... but this is only occasional. Once you get going, it runs much better. And as long as you stay out of boost then the car runs great.
I'm thinking my catalytic converter is clogged, or bad, or my second cylinder isn't firing completely... any ideas thoughts? Seems a bit out of my range of expertise... seems weird that it would only act up during boost. Maybe the recent work I had done wasn't done properly and the timing is off?
I recently had the following work done in December:
https://volvoforums.com/forum/volvo-...-repair-81413/
The CEL has been turning on and off randomly recently. The car appeared to be running good this morning so I punched the gas to get the turbo to initialize. I had a ton of backfire and rough running. CEL FLASHED for about 30 seconds and then turned off.
Took it to O'Reilly and had the following codes returned...
P0420: Catalyst System Efficiency Below Threshold Bank 1
P0456: EVAP System Leak Detected (very small leak)
P0302: Cylinder 2 Misfire
It can sometimes idle roughly (backfires) when it is first started up in the morning... but this is only occasional. Once you get going, it runs much better. And as long as you stay out of boost then the car runs great.
I'm thinking my catalytic converter is clogged, or bad, or my second cylinder isn't firing completely... any ideas thoughts? Seems a bit out of my range of expertise... seems weird that it would only act up during boost. Maybe the recent work I had done wasn't done properly and the timing is off?
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Looks like a new cat for this thing is over $800 smackers! 
Looks like I'll be going to the yard... and trying to find a friend that knows how to weld these things....
http://www.tascaparts.com/volvo/s40/...talytic-cnvrtr
Looks like it may be bolted on actually... can anyone confirm how much a pain this will be to do or not?
Edit: Looks like my local yard takes the catalytic converters off the car before they bring them out to the lot... ugh...
Looks like I'll be going to the yard... and trying to find a friend that knows how to weld these things....http://www.tascaparts.com/volvo/s40/...talytic-cnvrtr
Looks like it may be bolted on actually... can anyone confirm how much a pain this will be to do or not?
Edit: Looks like my local yard takes the catalytic converters off the car before they bring them out to the lot... ugh...
Last edited by Tindel; Feb 10, 2015 at 10:37 AM.
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Cats are very often changed unnecessarily imho. Do the troubleshooting to fix the other problems first. The cat code may be caused by the misfire.
Misfires are often caused by bad coil packs on these cars. Sparks plugs also, obviously.
For the turbo, one good nugget I picked up here recently is the oil supply can become blocked due to crud in the oil supply banjo bolt. Maybe worth a look.
If you do eventually need a cat, FCP Euro has one for your car for $270.00.
Misfires are often caused by bad coil packs on these cars. Sparks plugs also, obviously.
For the turbo, one good nugget I picked up here recently is the oil supply can become blocked due to crud in the oil supply banjo bolt. Maybe worth a look.
If you do eventually need a cat, FCP Euro has one for your car for $270.00.
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I just payed to have a shop replace the plugs and wires. I'm assuming they replace the coil packs, but I can't tell for sure. So I guess if I'm getting a cylinder misfire it is probably due to either poor gas system or exhaust system. So it may be the gas - and the small leak may be causing the problem? But that doesn't explain the backfire... it could just be the engine missing... hard for me to tell... it sure does run poorly under boost.
Another clue I just thought about is that the cabin can sometimes smell like exhaust. I'm going on a limb here, but with the occasional backfire issue I think the cat or muffler is clogging occasionally. But why would boosting the engine cause this? Maybe the additional excelleration? Maybe something is just clogged somewhere.
Will an emissions test tell me definitively if my cat is bad?
Another clue I just thought about is that the cabin can sometimes smell like exhaust. I'm going on a limb here, but with the occasional backfire issue I think the cat or muffler is clogging occasionally. But why would boosting the engine cause this? Maybe the additional excelleration? Maybe something is just clogged somewhere.
Will an emissions test tell me definitively if my cat is bad?
Last edited by Tindel; Feb 10, 2015 at 01:07 PM.
The emissions test will tell you for sure, but I think you have 3 separate problems as indicated by the codes you pulled.
The cat convertor trouble code is set by the bottom O2 sensor. The problem here is if the bottom O2 sensor has failed. In this case you need to replace the O2 sensor, erase the code, and drive the car to see if the code returns. Now my state does not have emissions testing so instead of a new O2 sensor I simply added an O2 sensor spacer. IPD sells one called a CEL Boss. Oxygen Sensor Spacer (CEL Boss) IPD 109553 3C1151
Every time I have had a misfire it was from bad coils. They get these tiny little cracks that allow the spark to jump to the head. I would never assume the shop replaced the coils unless you specifically paid them for the parts. I also ask for the old parts back after the work is done.
Last is the evac system leak. This can be the gas cap loose or missing or failed. (Filling the tank with the engine running?) Can also be cracked hoses. I've heard if your state has emissions testing it will fail for this.
The cat convertor trouble code is set by the bottom O2 sensor. The problem here is if the bottom O2 sensor has failed. In this case you need to replace the O2 sensor, erase the code, and drive the car to see if the code returns. Now my state does not have emissions testing so instead of a new O2 sensor I simply added an O2 sensor spacer. IPD sells one called a CEL Boss. Oxygen Sensor Spacer (CEL Boss) IPD 109553 3C1151
Every time I have had a misfire it was from bad coils. They get these tiny little cracks that allow the spark to jump to the head. I would never assume the shop replaced the coils unless you specifically paid them for the parts. I also ask for the old parts back after the work is done.
Last is the evac system leak. This can be the gas cap loose or missing or failed. (Filling the tank with the engine running?) Can also be cracked hoses. I've heard if your state has emissions testing it will fail for this.
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From: Toronto, Canada
x3 for coil packs...I would start there BUUUT did you use genuine Volvo plugs when you replaced them? I've been told that using other plugs can often cause all sorts of weird behaviour with this car...not sure why though.
The coil packs are not cheap so check your receipt. I would not be surprise if these WERE NOT replaced.
The coil packs are not cheap so check your receipt. I would not be surprise if these WERE NOT replaced.
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