Friday, April 4, 2014
How to Install a Welded Catalytic Converter
Catalytic converters filter a percentage of harmful emissions that a car produces. Environmental regulations dictate emission reduction methods that each state must follow. Automakers include this type of emission control equipment on new car and truck products. But when operation surpasses the limits of the converters ability to operate properly, it becomes necessary to replace it to maintain the same level of filtration as when the converter was new. When old catalytic converters remain in use after their life expectancy, the vehicle can fail tests of emission control. It is easy to install a new welded catalytic converter with some common shop tools.
Instructions
- 1
Elevate the car to a height where you have easy access to the exhaust system of the vehicle. Check for fluid leaks and be sure that the area around the catalytic converter is dry and free of fuels that may be ignited during the cutting out of the old converter(s). Mark the exhaust piping 3" before and after the converter, where the exhaust pipe is at its straightest and best condition. Compare that distance to the length of the new converter and adjust so that a proper connection will be made between the new converter and the old exhaust piping.
2Move the cutting torch tanks near enough to the work area for the cutting head to reach the converter and operate freely. Open the gas and air valves at the top of each tank and grab the igniter. Open the valves on the cutting handle in the proper proportion to turn the cutting flame from a flapping yellow to an intense, clear blue gas flame that can cut through metals. Press the air injection tab to create a cutting flame that can cut out the old converter quickly and easily. Cut around the marks made on the exhaust pipes outside of the converter inlet and outlet.
3Grind down and around the end of the exposed exhaust pipes with a handheld grinder and abrasive wheel. Depending on whether the new converter has expanded pipe ends that slide over the old exhaust pipes or not, the converter will need to be tack welded end to end using a stick welder. Prepare the ends of both exhaust and converter for welding. A welded catalytic converter is expected to have high performance throughout the life of the vehicle. Take time to get this step right before welding so that youll get a better result.
4Connect the ground to the exhaust pipe that will be welded and hold the new converter in place, edge to edge with the old exhaust piping. Protect your eyes with welding glasses and touch the stick to the joint of the two parts. After the connection is made, hold in place for three seconds, then pull away. Repeat this process again on the opposite side of the piping and then on the other end of the converter. This tack weld will hold the pieces together for complete welding later. Complete the converter welding around both inlet and outlet pipes of the converter so that the weld is complete and free of leaks.
5Transfer old converters and exhaust tubing that can be recycled into a recycling bin. While the converter may become clogged and unable to be used, the precious metal can be recycled. After each and every upgrade or maintenance job there is something you can do to help the environment. Do your part by recycling everything that needs to be disposed of properly and find that your shop stays clear of dangerous debris.
