Vauxhall Astra 1.6 (z16xep Engine) 10/03-12/05 Catalytic Converter Cat
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On a properly functioning vehicle regeneration will occur approximately every 500 miles (this is very substantially dependent on the vehicle and driving conditions). Why do DPFs Fail The most common reason for the failure of a DPF is that it has become too "clogged" with soot to be able to regenerate. It is easy in this instance to simply assume the DPF is at fault and replace it, but if no diagnostic work is carried out it is likely the new DPF will fail quickly (within 200 miles) Initial Investigation The best source of information is the vehicle owner/driver. The information they provide can be invaluable in identifying the fault.
Occasional harder driving in low gears should be enough to burn off the soot in these cases. How long has the DPF warning light been illuminated Many DPF problems are caused by simply ignoring the warning lights that advise that the DPF needs to be regenerated. Once the DPF is around 45% full the vehicles Electronic Control Unit makes changes to the fuel injection timing to increase the exhaust temperature to burn off the particulates. If the journeys completed at this point are stop/start the conditions required for regeneration may not be met and the warning light will be illuminated indicating that the DPF is starting to become blocked.It should be possible to clear this warning by driving at speeds greater than 50mph for around 20 minutes (the engine must be running at a minimum of 2500 rpm). If the warning light continues to be ignored or conditions for regeneration are not met the level of soot in the DPF will continue to increase, and at around 75% full the DPF will have to be regenerated by a dealer or specialist garage.
If the vehicle has recently been serviced it is worth checking that the correct type of oil has been used. Most DPF vehicles require a special type of low ash oil, and using the incorrect oil can lead to problems during the regeneration process. If the vehicle uses a fuel additive system to aid regeneration it should be checked that the additive tank has been filled.
The Following Items Must be Checked - air flow meter, engine and turbo wear, injectors (in case they are leaking or over fuelling) turbo hoses and the intercooler must be checked for leaks, correct glow plug & glow plu controller operation and the main engine ECU should also be checked for any malfunctions. DPF Installation & Set Up Once the fault that caused the previous DPF to fail has been rectified the new DPF can be fitted. The new DPF should be fitted loosely to line it up correctly with the rest of the exhaust system before tightening it up. This includes telling the car that a new DPF has been fitted, resetting the ash counter and calibrating the differential pressure sensor. Failure to complete the setup procedure correctly will cause the new DPF to become blocked as the vehicle is unaware that a new DPF has been fitted and therefore the regeneration system will not have been reset.A forced regeneration may be part of the reset procedure and some vehicles may require and ECU software update. If all guidelines have been followed a new aftermarket DPF will work in the same way as the O. Specification unit did prior to failure. We have experienced an incorrectly diagnosed/setup vehicle to block a new DPF within 50 miles but around 200 miles is most common. Although every effort is made to ensure our catalytic converters will not fail, sometimes a problem with the vehicle will cause them to break down. Road Damage This is external damage caused to the catalytic converter by hitting solid objects in the road, i. Plugged or Contaminated Plugged or contaminated catalytic converters are caused by using the wrong sort of fuel in your car. Using leaded or lead replacement fuel will plug up the monolith and cause it to stop working. A similar thing will happen if fuel additives are used that are not suitable for use with a catalytic converter. Oil Fouled This is caused by oil getting into the exhaust system and contaminating the catalytic converter. The most likely cause would be a failing seal or gasket. Broken Substrate The monolith is usually broken when it is impacted by an object or when it suffers a sudden change in temperature. If the catalytic converter suffers road damage the monolith inside can be cracked due to it being crushed by movement of the steel can. The use of exhaust paste before the catalytic converter can cause the monolith to break. When the exhaust paste has hardened small pellets may break away and shoot into the catalytic converter. The monolith will gradually be destroyed by these pellets and break down.
The catalytic converter can also be damaged by excessive engine vibration. Overheating There are many problems that can cause the catalytic converter to overheat or fail.The most common cause is unburned fuel entering the catalytic converter. Faulty spark plugs or ignition leads will cause the engine to misfire sending unburned fuel into the catalytic converter leading to overheating and failure. A Oxygen Sensor An oxygen sensor collects readings and sends information to the electronic control unit. This information is used to control the air/fuel mix. If the oxygen sensor is faulty the air/fuel mix will not be corrected and excess fuel will enter the catalytic converter causing it to overheat and fail. B Fuel Injection Systems If a fuel injector is leaking internally or dribbling fuel into the engine the excess fuel will enter the exhaust system causing the catalytic converter to overheat and fail. C Map Sensors Map Sensors tell the electronic control unit the load the engine is under and the amount of fuel entering it. If a map sensor fails it causes the engine to run too rich which causes the catalytic converter to overheat and fail. D Carburettor Systems A worn or defective carburettor can cause a catalytic converter to overheat and fail.
Problems such as improper float or air/fuel mix adjustments, worn metering rods or a faulty choke system can cause too much fuel to enter the engine and then the exhaust system causing the catalytic converter to overheat and fail. E Canister Purge Valve Control This vacuum operated valve vents fuel vapour from the carburettor bowl to the charcoal canister.If the vacuum is breached the charcoal canister will flood causing the air/fuel mixture to become too rich which will cause the catalytic converter to overheat and fail. If your vehicle has failed the MOT emissions test or your catalytic converter is rattling or blocked you will need to include a scanned copy of an engine emissions report. The most common causes of a blocked DPF are listed below.
- Brand: EEC
- Manufacturer Part Number: VX6084T
- Reference OE/OEM Number: 13106851
- Other Part Number: BM91424H