A catalytic converter converts the harmful exhaust gases produced by the engine into less harmful emissions before they leave the vehicle's exhaust system. The catalytic converter looks similar to a muffler. It is typically a stainless steel housing with a ceramic honeycomb inside that is impregnated with platinum, palladium, and rhodium.

These elements help clean up harmful exhaust gases that otherwise would be expelled from the tail pipe. It is common for a four-cylinder engine to be equipped with one or two catalytic converters, while six and eight-cylinder engines can have up to four. The catalytic converter has multiple sections, commonly referred to as beds. Each contains specific catalyst elements that work at a temperature of at least 400 degrees F to promote specific chemical reactions.

This converts harmful CO, HC, and NOx exhaust gases into less harmful CO2, H2O, and N gases that are released from the vehicle's exhaust pipe. The first section of the catalytic converter is called the reduction bed and is coated with rhodium.

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It is called the reduction bed because its purpose is to reduce the NOx gases back in to harmless nitrogen and oxygen. The next section of the catalytic converter is the oxygen storage bed, which is coated with cerium. Its purpose is to maintain an ideal level of oxygen for use by the rear of the converter. It does this by storing and releasing the oxygen that gets released from the reduction of NOx in the previous reduction bed. The oxygen is then available for use in the final oxidizing bed, which is coated with platinum and paladium. The purpose of the oxidizing bed is to complete the combustion of CO by adding oxygen.

The oxidizing bed also uses oxygen to burn any of the raw HCs that still remain in the exhaust gases. If the engine is running properly, the catalytic converter should last the life of the vehicle. Failure is commonly caused by too much raw fuel entering the converter, and example of which would be the result of an engine misfire. Too much unburned fuel can coat the catalyst causing the converter to stop working, the converter can also overheat and break apart inside becoming restricted or 'plugged'. Your catalytic converter is covered by the vehicle's emissions warranty, which extends beyond the manufacturer's factory warranty. Along with other emission control devices, federal law requires manufacturers to replace a defective cat for up to 15 years or 150,000 miles. Because this coverage varies by state and vehicle type, refer to your owner’s manual for specific warranty information.

Depending on the type of failure, different diagnostic approaches are necessary. For a lack of power concern, a back pressure test should be performed to check for a plugged converter. If an illuminated check engine light leads to a fault code that indicates a failing converter, the manufacturer recommended diagnostic procedures should be followed to confirm the fault. A catalytic converter could also have a noise concern (exhaust leak or rattling type noise). In this case, diagnosing the issue would involve duplicating the noise and confirming in is coming from the catalytic converter. A failed catalytic converter will require replacement.

A vehicle may have more than one converter, it is very important to make sure the correct converter is identified when ordering parts and installing the new converter. Most converters are bolted in place in the exhaust system. If not bolted, the converter would be welded or clamped in place. A bolted in converter can be replaced by unbolting (penetrating oil should be used prior to attempting to remove any exhaust system bolts) the old converter and bolting the new one in.

If a converter is welded in place, the old one will need to be cut out and the new converter installed - either by welded or using exhaust pipe clamps as required. Catalytic converters are normally placed near the engine. Some are built directly into the exhaust manifold as they work most efficiently when hot. Some cats can exceed 1,000 degrees, so never touch a catalytic converter while an engine is running or after its been shut off. Many hours are required before a catalytic converter is serviceable, so proceed with caution anytime you’re working with your exhaust system. Care should always be taken when working around hot exhaust components.

An engine not running properly is nearly always the cause of a catalytic converter failure. Engine operation should the thoroughly checked after replacing a faulty converter.

Failure to do so could result in failure of the new converter. Catalytic converters are vehicle-specific, and special attention needs to be paid to the quality of parts used. Cheaper cats are to be used with extreme caution, as they may not perform adequately for vehicle emission tests and inspections. Some states like California allow only certified cats to be used for replacement. A High-quality Original Equipment Manufacturer (OEM) replacement CAT is highly recommended.

Rust build up on exhaust system components is not uncommon, penetrating oil should be used on threads prior to attempting removal. A new Catalytic Converter can be quickly damaged if installed in a vehicle with a poorly running engine. Proper diagnoses should always be following prior to replacing a catalytic converter, just because a fault code points to the converter, does not guarantee replacing it will correct the problem. Many vehicles have more than one converter, care should be taken to make sure the correct converter is diagnosed or replaced. A Catalytic Converter can either be bolted or welded in place. In most cases a converter bolted in place can be removed using basic hand tools (be sure to use penetrating oil before attempting to remove exhaust system components). If the converter is welded in place, some sort of cutting device will be necessary to remove it.

Be sure to check your vehicle to see what you have before attempting this repair. Having the necessary tools on hand before starting will help the job run smoothly. It is very important to reinstall any heat shields that were removed in order to replace the converter because of the heat generated during normal operation.

Modern engines use one or a pair of oxygen sensors (O2 sensors) in the exhaust stream to determine how much fuel the engine is burning relative to air intake. This is important because if there is too little fuel in the mix, the engine will run much hotter, damaging it and overheating the cat.

According to some dealership mechanics, Camrys seem to have a defect in the O2 sensor that causes it to fail prematurely, but does not trigger a 'check engine' light. Upon sensor failure, the computer goes into 'open-loop' operation and uses its best guess on air/fuel ratio to run the engine, which will often be too lean in lower altitudes.