vvEPA
Umterj States OPA 87-023
Environmental Protection January 1989
Age'icv
Ait and Radiation
Aftermarket
Catalytic
Converters
Guide to Their
Purchase,
Installation, and
Use
Printed on Recycled Paper
-------
By now most Americans are familiar with at
least the name "catalytic converter."
Catalytic converters are the most important
pollution-control devices that have been
installed on U.S. passenger cars and light-duty
trucks since 1975.
The term "aftermarket converter" still
requires some explanation. An aftermarket
converter is any catalytic converter that is not
identical to the new original equipment
converter that was on a vehicle when it left the
manufacturer. Aftermarket converters can be
either used refurbished but original-equipment
converters or brand-new "universal" converters
produced to fit a wide variety of vehicles'
Manufacturer-installed original-equipment
converters have been custom-designed to fit
and perform properly on a specific vehicle and
to last its whole lifetime if the vehicle is
properly tuned and maintained. Unfortunately,
not all drivers have given their vehicles the
proper maintenance needed to preserve their
converters. As a result, some have been ruined;
other converters have been removed altogether.
Therefore, a large number of car owners may
need to replace disabled or removed converters
either immediately or in the near future.
To ensure the effectiveness of the converters
available to consumers, EPA decided that
guidelines were needed to govern the sale,
installation, and use of aftermarket catalytic
converters. This booklet explains what those
guidelines are and how they will be enforced.
EPA's aftermarket-converter guidelines apply
to people engaged in the business of
automotive service and repair as well as anyone
engaged in the business of repairing, servicing,
leasing, selling, or trading motor vehicles (or
motor vehicle engines) or operating a motor
vehicle fleet. Under the authority of Section
203(a)(3) of the Clean Air Act, all these persons
have been prohibited from installing or selling
aftermarket catalytic converters that have not
met the criteria detailed in EPA's "Sale and Use
of Aftermarket Catalytic Converters," an
interim enforcement policy published on
August 5, 1986.
-------
This interim policy applies only to
aftermarket converters manufactured or
refurbished after December 18, 1986. Under the
policy, all aftermarket converters installed or
sold for installation in the United States after
January 1, 1988, must meet EPA's
requirements.
Violators of this policy are now subject to a
civil penalty of up to $10,000 for each improper
installation. In addition, all persons subject to
the policy are required to keep certain records
pertaining to the aftermarket converters they
install.
If you still have questions after reading the
information provided below, please contact
EPA by writing Field Operations and Support
Division (JHIHfcU.S. Environmental
Protection Agency, Washington, D.C. 20460
MEW MAILCODE <6J+O6J)
MEW TELEPHONE MUMbER <2O2> 333-91DO
-------
The Need
for Special
Requirements
Aftermarket catalytic converters may be an
alternative for owners of vehicles whose
original manufacturer-installed converter has
been ruined or removed. If a vehicle is out of
warranty, the price of a new original-equipment
converter (or set of converters) can be
anywhere from $300 to $1,000, This expense is
often a deterrent to prompt and proper
maintenance. In addition, these
original-equipment converters are sometimes
scarce and hard to find. Their unavailability
raises further barriers to vehicle owners in
search of proper maintenance.
Since the effectiveness of converters depends
on their proper installation, performance, and
durability, EPA is now requiring aftermarket
converters to meet certain minimum standards.
The Agency is also requiring installers of
aftermarket converters to select the proper ones
for each installation.
These requirements make everyone "play by
the same rules." In doing so, they maximize the
benefits to air quality that are the goals of the
policy. The policy also sets forth certain
warranty, reporting, and recordkeeping
requirements that make it possible for EPA to
enforce the aftermarket-converter policy and
ensure that customers get what they pay for.
Types of
Aftermarket
Converters
There are two main categories of aftermarket
converters: new and used. New aftermarket
converters are not new original-equipment
converters custom-designed to work on a
certain vehicle and installed at the factory.
Instead they are products manufactured for
installation later in the life of a vehicle, and
again unlike new original-equipment
converters, new aftermarket converters are not
designed for use on one particular vehicle
alone. The predominant type of new
aftermarket converter is "universal," built to
control—within certain limits—emissions on a
wide variety of vehicles. New
4
-------
aftermarket-converter manufacturers are
required to provide warranty protection.
Used aftermarket converters are usually
"reconditioned" original-equipment converters;
as a result, they can only be installed on the
type of vehicle or vehicles for which they were
originally intended. Used converters are not
required to be covered by warranties.
Both new and used aftermarket converters
fall into three sub-categories: oxidation
converters, three-way converters, and
three-way-plus-oxidation converters
TWO WAY
(OXIDIZING)
N,
HC
CO
PLATINUM
PALLADIUM
H20
CO,
HC
CO
•wl
NOj
HC
CO
THREE WAY
RHODIUM
PLATINUM/PALLADIUM
THREE WAY/AIR
H.,0
COj
Oxidation converters are the early generation
of converters that were designed to reduce
hydrocarbons (HC) and carbon monoxide (CO).
Oxidation converters usually contain platinum
and/or palladium.
In 1980-81—earlier on some California
vehicles—most vehicle manufacturers began
using three-way converters (TWCs) designed to
reduce nitrogen oxides (NOX) in addition to HC
and CO. Three-way converters usually contain,
in addition to platinum and/or palladium, the
noble metal rhodium. Coinciding with the
installation of TWCs, vehicles were fitted with
computer control systems and oxygen sensors
usually employed to precisely regulate the air to
fuel (A/F) ratio and mixture controls.
Some converters have both a three-way
catalyst and an oxidation catalyst together in
-------
one housing or "can." These are called
three-way-plus-oxidation (TW + OC) or
dual-bed converters. These converters have air
injected between the two sections to help the
two different chemical reactions occur.
Three-way catalysts require a slightly richer
mixture while the oxidation converter requires a
lean mixture. Hence, air is injected after the
three-way "bed" and before the oxidation
"bed."
It is important to install the correct converter
type if it is to operate effectively and not have
an adverse effect on the performance of the
vehicle or its emission-control system.
Which
Converters
Comply
Many people in the automotive business, not to
mention an even larger number of drivers, are
unsure which aftermarket converters do—and
which do not—satisfy the provisions of the new
EPA policy.
Fortunately, there are easy ways to tell if an
aftermarket converter meets EPA requirements.
A converter that meets those requirements
must be properly labeled and warranted to
meet federal durability and performance
standards.
New aftermarket converters are required to
have a five year, 50,000 mile warranty on the
converter shell and end pipes. They are also
required to be warranted to meet EPA's
emission performance standards for 25,000
miles when the vehicle is properly used and
maintained.
Used converters are only required to meet the
performance requirements that applied at the
time of sale; no additional warranty is required.
All manufacturers of new and used
converters who meet the EPA requirements
must state that fact in writing. Usually this
statement is made in the warranty information
or vehicle application catalog.
-------
Labeling
Requirements
Required labels on the converters will have a
.series of letters and numbers that appear in the
following format:
N/XX/YYYY/ZZZZ for new converters
U/XX/YYYY/ZZZZ for used converters
Where N indicates a new converter
U indicates a used converter
XX is the manufacturer's code issued by EPA
YYYY is usually a numerical designation of the
part or the vehicle it should go on
ZZZZ is the month and year of manufacture
(e.g., "0187" for January 1987)
Note: Converters manufactured for sale in
California may have the letters "CA" in place of
the "N" or "U." Since California's standards are
more stringent than EPA's, these converters will
also meet EPA requirements.
Many trade publications-will also carry
information about which companies have
converters that meet EPA requirements.
If you're still not sure, call EPA at (202)
382-2640.
POSSIBLE LABEL
LOCATIONS
Unacceptable
Used
Converters
It is a violation of EPA's policy to install a used
converter from a salvage yard unless it has
been properly tested and labeled. The same
applies to selling such a converter for reuse.
7
-------
Similarly, it is a violation to install an
untested converter brought in by a customer,
even if the customer insists that the converter
came off of the same vehicle.
Salvage or junk yards are considered liable
for tampering if they sell converters that have
not been tested or do not meet the
requirements outlined in EPA's policy,
provided that the converters in question have
been installed by parties subject to Section
203{a)(3) of the Clean Air Act.
Manufacturer
Requirements
Manufacturers of new converters are required
to run two worst-case tests. Vehicles equipped
with the new converters are driven for 25,000
miles each and then subjected to testing. The
testing must show that the converters meet
certain performance standards for reduction of
emissions.
Reconditioners or remanufacturers of used
converters may only use those that were
original-equipment converters. Furthermore,
they must bench-test each converter to ensure
satisfactory performance.
Both new and used converter manufacturers
must comply with certain EPA recordkeeping
and reporting requirements. They must also
have a system to notify installers of the EPA
requirements and restrictions that apply.
Manufacturers of new converters are also
required to provide a warranty on the converter
shell and end pipes for five years or 50,000
miles, whichever comes first, and for 25,000
miles on converter emission performance.
All converters are required to be labeled as
previously described.
Proper
Installation
People engaged in automotive service or repair
need to know under what circumstances they
can install aftermarket converters.
Generally, there are only three situations
when you can install an aftermarket converter:
-------
• If the converter is missing from the vehicle
when brought in for exhaust system repair.
• If the state or local inspection program has
determined that the existing converter has been
lead-poisoned, damaged, or otherwise needs
replacement.
• If the vehicle is more than five years old or
has more than 50,000 miles, and there is a
legitimate need for converter replacement that
has been established and appropriately
documented (e.g., a plugged converter or
unrepairable exhaust leaks).
Any other converter replacement must be
with a new original equipment converter—or its
equivalent.
Aftermarket converters cannot be used for
replacement:
• If the existing converter is present and
functioning properly.
• If the replacement is under recall or warranty.
• If the vehicle is returning from overseas use.
Choosing
the Right
Converter
Installers should check the manufacturer's
catalog to determine the proper converter for a
driver's car or truck. Remember that
particularly large vehicles and engines may not
be covered by most manufacturers. After
you've selected the correct type of converter,
consider engine-size and vehicle-weight
limitations. If the converter was not designed to
cover a large enough vehicle or engine,
installing it may lead to its destruction; it may
also cause vehicle or engine problems and void
the converter warranty, in addition to violating
federal law.
Installation
Requirements
Besides installing aftermarket converters only in
the three situations outlined above, installers
have other requirements and restrictions to
-------
keep in mind. These include completely
documenting the need for converter
replacement, properly installing the correct
converter on the vehicle, and informing
customers of their rights as well as certain
restrictions.
Specifically, installers must:
• Make sure that if the replacement is not
required by a state or local program, both
customer and installer sign a statement
concerning why the converter was replaced.
(Manufacturers either provide a generic version
of this kind of statement with the converter, or
they have an example printed in their catalogs.)
• Keep a copy of the program representative's
statement or order if the converter replacement
was required by a state or local program.
• See to it that the invoice for replacement
includes the customer's name and complete
address, and the vehicle's make, model year,
and mileage, as well as the reason for
replacement.
• Retain copies of the above invoices and
statements for six months. Also, retain the
replaced converters for 15 days, and make sure
they are marked to identify which customer's
car they came from.
• Install the converter in the same location as
the original.
• Install the same type of converter as the
original: oxidation, three-way, or three-way-
plus oxidation (dual-bed). This information is
sometimes available on the emissions tune-up
label or in the manufacturer's application
catalog.
• Install the proper converter for the vehicle as
determined and specified by the converter
manufacturer. There are engine-size and
vehicle-weight limitations that make it
inappropriate to install certain converters on
certain vehicles. Therefore, the catalog should
always be consulted for the correct application.
• Make sure the converter is properly
connected to any existing air injection
components.
10
-------
• Install all the other required converters the
vehicle would have originally come with unless
the converter manufacturer has stated in
writing that the aftermarket converter is
designed to replace more than one converter.
• For new aftermarket converters, fill out the
warranty information card supplied by the
manufacturer and give it to the vehicle owner
or operator.
Legal Penalties
Converter installers and others subject to
Section 203(a)(3) should be aware of the legal
penalties for failure to comply with EPA's
aftermarket converter policy. They should also
understand the rationale behind the penalties: it
is a violation of federal law to install or use the
wrong type of catalytic converter because such
a converter is likely to increase the amount of
pollution coming out of a vehicle.
Penalties for violations by service or repair
shops, or fleet operators are up to $2,500 per
violation. (Each improper installation is
considered a separate violation.) New car
dealers can be penalized up to $10,000 per
violation. Also, any person who causes a
violation of Section 203(a)(3) could face the
same penalty as the installer.
Customer Guidelines
Customers need to know certain things before
they buy an aftermarket converter:
• First and foremost, that the original converter
on a car or truck was designed to last the life of
the vehicle if it was properly used and
maintained, and it is warranted by the vehicle
manufacturer to last at least five years or 50,000
miles, whichever comes first. Customers should
consult their vehicle warranty booklets for
further information.
• Many drivers worry about the effect catalytic
converters will have on their cars'
performances. They should understand that an
original-equipment converter is an integral part
of the vehicle's emission and engine system
that has been designed to achieve the lowest
possible emissions consistent with optimal
performance.
11
-------
However, new aftermarket converters are
generally designed to be installed on a wide
range of vehicles. As a result, the backpressure
changes created may, in some cases, adversely
affect vehicle and engine performance. Used
converters are not required to have a warranty,
so their performance and remaining life is
dependent on the history of their prior usage.
In general, aftermarket converters are not
designed to perform as well as the converters
originally installed on the vehicle by the
manufacturer. Aftermarket converters will,
however, provide acceptable performance at a
lower cost than new original-equipment
converters.
• Competent installation is vital. Backpressure
and heat are created during the operation of
converters, and there are also variations in the
effectiveness and compatibility of some
emission systems with certain converters.
Therefore, it is important to make sure that the
converter installed is the proper one for a
customer's car or truck. Each installer should
check the application catalog that describes the
vehicles on which each converter can be
installed.
• Proper maintenance is also extremely
important. Next to installing the proper
converter, probably the best way to keep the
converter operating properly and under
warranty is to ensure that the vehicle is
properly tuned. A properly tuned and operated
vehicle is critical for long converter life.
Otherwise, drivers may ruin their converters,
void their warranties, and possibly cause
engine damage along with higher emissions.
Drivers are not subject to legal penalties
under EPA's aftermarket converter policy, but
they can suffer in a different way: from
impaired vehicle performance and increased
pollution caused by using the wrong catalytic
converter. In some severe cases, converter or
engine overheating could occur, resulting in
unsafe operation and possible engine damage.
These conditions—or even simply using the
wrong part on a vehicle—may allow the
converter manufacturer not to honor the 25,000
mile or the five year/50,000 mile warranty.
------- |