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Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

I have a 2012 corsa d 1.2l petrol. Whenever I drive it it runs fine for.sbout 3 minutes after which it doesn't go past 3000 rpm. The car doesn't show any electrical issues. I've run a cylinder compression test and it passed. I installed new spark plugs and cleaned the intake manifold. The car seems to make a loud noise around the catalytic converter but it doesn't produce black smoke which I read is one of the symptoms. I'm probably gonna try to unbolt the converter and see if that fixes the issue. Is there anything else thos could be?

Vauxhall Corsa - Diagnosing catalytic converter - elekie&a/c doctor
It could be a blockage in any part of the exhaust system. I would try to remove the top lambda sensor first , much easier than the complete catalyst and manifold. If the engine free revs , then there’s a blocked part of the exhaust, not necessarily the catalyst.
Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

Hello, thanks for the advice. The top lambda sensor is also above the catalytic converter so how would removing it exclude the catalytic converter. Just trying to understand thanks.

Vauxhall Corsa - Diagnosing catalytic converter - paul 1963

Hello, thanks for the advice. The top lambda sensor is also above the catalytic converter so how would removing it exclude the catalytic converter. Just trying to understand thanks.

It wouldn't but it would prove there's a blockage somewhere.

Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

So it would allow the exhaust gases to escape through the lambda port and if it restores power that means it's catalytic converter?

Vauxhall Corsa - Diagnosing catalytic converter - paul 1963

No it would prove there's a blockage somewhere in the exhaust rather than a problem elsewhere.

Vauxhall Corsa - Diagnosing catalytic converter - elekie&a/c doctor
The only way to eliminate or prove the cat is blocked , would be to unbolt it from the lower flange where it meets the rest of the exhaust system. That’s usually an issue as it’s likely all the nuts and bolts will be seized or corroded .
Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

Got it, thanks for your help. I'll give that a go.

Vauxhall Corsa - Diagnosing catalytic converter - bathtub tom

I had a similar problem and managed to disconnect the exhaust behind the cat. It ran freely (if noisily) proving an obstruction was further downstream. Turned out the back box had collapsed internally (corrosion) allowing the wadding to partially block the exit. An hour or so 'fishing' down the tailpipe with a piece of wire bent to a hook at the end pulled out all the wadding. Strangely enough, I thought it didn't sound any louder and passed a couple of more MOTs like it.

Vauxhall Corsa - Diagnosing catalytic converter - edlithgow

Suspecting an exhaust restriction might be responsible for some mysterious intermittent running problems, and not finding intake manifold pressure readings (which are supposed to be diagnostic for this) very interpretable, I decided to try direct measurement.

Not having a sensor port (or a catalytic converter) to work with, I made myself a spacer where the front and back exhaust sections join, with a wee T- pipe to take a pressure gauge. Results didn't suggest much restriction, but just in case, I back flushed the disconnected rear section of pipe with a garden hose.

I got some soot and a bit of beercan lid (thicker than the rest of the can and thus less likely to melt), derived from my internal "flame spray" treatment of the exhaust with aluminium and portland cement. This lid could have been an occaisional restriction, but the problem persisted after its removal, and was probably a vacuum leak, since it went away after painting the carb and intake manifold with multiple coats of sunflower oil.

If I had a restricted catalytic converter or DPF I'd probably try back flushing it. The way they are built probably indicates flushing both ways.

Edited by edlithgow on 07/08/2024 at 09:13

Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

Hi, thanks for your reply. Today i removed the lambda sensor and the cur run better then ever even when fully warmed up it got to 7k rpm in a split second. This weekend i will try disassembling the exhaust starting from the rear and trying in between. Hopefully i get lucky and its just the back box.

Vauxhall Corsa - Diagnosing catalytic converter - Michal Rajda

Hi. I removed the lambda sensor today and the car run better then ever running freely to 7k rpm in a split second even after 10 minutes of driving. Is there any tool that would help me diagnose a more specific g part of the exhaust? Anyhow if not i will start taking it apart this weekend to see any blockages. Thank you.

Vauxhall Corsa - Diagnosing catalytic converter - elekie&a/c doctor
An infra red thermal gun will give some indication of any hot spots in the exhaust system .
Vauxhall Corsa - Diagnosing catalytic converter - edlithgow
An infra red thermal gun will give some indication of any hot spots in the exhaust system .

Would you expect hotspots to coincide with blockages?

I wouldn't, particularly, (in the abscence of any experience) and I'd think, without experience, or a "normal" system for comparison, IR readings might be hard or impossible to interpret.

I suppose the cat might get hot in normal operation due to it "burnng "HC, so if its unusually cold that might indicate a blockage, but it wouldn't tell you where it was. The OP already seems to have pretty good indication of a blockage, which is probably in the catalytic converter.

It MIGHT be that the system would be hot upstream of a blockage and cold downstream of it, or it could be that a blockage reduced overall throughput so the whole system was cooler. Not sure which I would expect.

Worth a try since he's going to have to take it apart anyway,

Edited by edlithgow on 09/08/2024 at 07:22