Category Archives: Catalytic Converter

Catalytic Converter Do’s & Don’ts:

Catalytic Converter Do’s & Don’ts:

Things to consider once your Catalytic Converter has been replaced with a new Zetti Emissions component.

• It is highly recommended that you use high octane fuel, for example 95 or 98 Octane and avoid Ethanol blended fuels. Ethanol blended fuels severely decrease Catalytic Converter efficiency & life span.

• If your vehicles Catalytic Converter was replaced due to an Check Engine Light issue, (usually the P0420 fault code) it is highly recommended that you also have further checks completed by your chosen mechanical workshop to ensure your vehicle does not have additional non-Catalytic Converter related faults.

Engine-Warning-Light

• If you experience any further issues with the Check Engine Light illumination after replacement of a Catalytic Converter, please make your exhaust specialist aware immediately as continued driving of the vehicle may lead to further Catalytic Converter or other mechanical issues.

• Continuing to keep your vehicle properly maintained, for example replacing air and fuel filters and choosing the correct oil for your vehicle is also critical to Catalytic Converter efficiency and in turn life span.

 

Thank you for choosing a Zetti Emissions replacement part on your vehicle. If you have any further questions, please contact your exhaust specialist today.

Summary of Emission Requirements

Timetable for Adoption of ADR Emission Requirements: Euro 2-6 Australian and EU Introduction

Light Petrol, LPG and NG Vehicles
Australian Introduction EU Introduction
Euro 2 adopted in ADR79/00 from 1/1/03 to 1/1/04 01/1996
Euro 3 adopted in ADR79/01 from 1/1/05 to 1/1/06 01/2000
Euro 4 adopted in ADR79/02 from 1/7/08 to 1/7/10 01/2005
Euro 5 adopted in ADR79/03 (Core Euro 5)* from 1/11/13 and ADR79/04 (Full Euro 5) from 1/11/16 09/2009 New Models
01/2011 All Models
Euro 6 to be adopted in ADR79/05 from 1/7/17 to 1/7/18 09/2014
Light Diesel Vehicles
Australian Introduction EU Introduction
Euro 2 adopted in ADR79/00 from 1/1/02 to 1/1/03 01/1996
Euro 3 (never formally adopted) 01/2000
Euro 4 adopted in ADR79/01** from 1/1/06 to 1/1/07 01/2005
Euro 5 adopted in ADR79/03 (Core Euro 5) from 1/11/13 and ADR79/04 (Full Euro 5) from 1/11/16 Euro 5a 09/2009 New Models 01/2011 All Models
Euro 5b 09/2011 New Models 01/2013 All Models
Euro 6 to be adopted in ADR79/05 from 1/7/17 to 1/7/18 09/2014

Full details of EU Emissions introduction available at:
Source: dieselnet.com/standards/eu/ld.php
Source: infrastructure.gov.au/roads/environment/emission/index.aspx

ADR79/05 will be formally determined by the Minister when UN Regulation 83 has been amended to incorporate the Euro 6 standards.

Note: In each case, the first date applies to vehicle models first produced on or after that date, with all new vehicles required to comply by the second date.
Euro 5a = Without new particulate measurement technique
Euro 5b = With new particulate measurement technique


*The “core” Euro 5 requirements which apply in ADR79/03 require compliance with all the technical requirements of UN Regulation 83/06 except that ADR79/03:

• allows the provision of PM mass emissions data based on the previous UN R83/05 (Annex 4) Type I test procedure (with a PM mass emissions limit of 0.005g/km) in lieu of data collected under the revised test procedure (Annex 4a of UN R83/06) which specifies a limit of 0.0045g/km);

• accepts a relaxed OBD threshold limit (80mg/km) for PM mass for M and N category vehicles of reference mass >1760kg;

• does not require compliance with the PM number limit specified for diesel vehicles in UN R83/06;

• does not require compliance with the In Use Performance Ratio for OBD systems in UN R83/06;

• does not require the NOx monitoring for petrol vehicles specified in UN R83/06; and

• only requires flex fuel vehicles to meet the Type VI test when tested on petrol (details of requirements for flex fuel vehicles to meet the Type VI test under ADR79/04 and ADR79/05 at low temperature to be determined by 31 December 2011).

**Euro 4 was first adopted for light diesel vehicles in ADR79/01, but was effectively replaced by ADR79/02 from 1/7/08.

 

Summary of Emission Requirements for New Petrol Passenger Cars in Australia 1972 – 2018

Standard Date Introduced # Exhaust Emission Limits (Petrol Vehicles) Source Standard / Test Method
HC CO NOx PM
ADR26 1/1/72 NA 4.5% by vol NA NA Idle CO test
ADR27 1/1/74 8.0 – 12.8 g/test 100 – 220 g/test & 4.5% by vol NA NA ECE 'Big Bag'
ADR27A 1/7/76 2.1 g/km 24.2 g/km 1.9 g/km NA US '72 FTP
ADR27B 1/1/82 2.1 g/km 24.2 g/km 1.9 g/km NA US '72 FTP
ADR27C + 1/1/83 2.1 g/km 24.2 g/km 1.9 g/km NA US '72 FTP
ADR37/00 1/2/86 0.93 g/km 9.3 g/km 1.93 g/km NA US '75 FTP
ADR37/01 1/1/97 – 1/1/99 0.26 g/km 2.1 g/km 0.63 g/km NA US '75 FTP
ADR79/00 1/1/03 – 1/1/04 0.25*g/km 2.2 g/km 0.25* g/km NA UN R83/04 (Euro 2)
ADR79/01 1/1/05 – 1/1/06 0.2 g/km 2.3 g/km 0.15 g/km NA UN R83/05 (Euro 3)
ADR79/02 1/7/08 – 1/7/10 0.1 g/km 1.0 g/km 0.08 g/km NA UN R83/05 (Euro 4)
ADR79/03** 1/11/13
(new models only)
0.1 g/km
0.068 g/km (NMHC)***
1.0g/km 0.06 g/km 0.0045g/km**** UN R83/06 (Euro 5)
ADR79/04 1/11/16 0.1 g/km
0.068 g/km (NMHC)***
1.0g/km 0.06 g/km 0.0045g/km**** UN R83/06 (Euro 5)
ADR79/05 1/7/17 – 1/7/18 0.1 g/km
0.068 g/km (NMHC)***
1.0g/km 0.06 g/km 0.0045g/km**** UN R83/TBA (Euro 6)

Source: www.infrastructure.gov.au/roads/environment/emission/index.aspx

# where 2 dates specified, first date applies to vehicle models first produced on or after that date, with all new vehicles required to comply by the second date.

+ ADR27C introduced a number of administrative changes, based on procedures of ADR37/00.

* ADR 79/00 has a combined HC+NOx limit of 0.5, so the HC:NOx split is indicative only.

** The “core” Euro 5 requirements which apply in ADR79/03 require compliance with all the technical requirements of UN Regulation 83/06 except that ADR79/03: 

• allows the provision of PM mass emissions data based on the previous UN R83/05 (Annex 4) Type I test procedure (with a PM mass emissions limit of 0.005g/km) in lieu of data collected under the revised test procedure (Annex 4a of UN R83/06) which specifies a limit of 0.0045g/km);

• accepts a relaxed OBD threshold limit (80mg/km) for PM mass for M and N category vehicles of reference mass >1760kg;

• does not require compliance with the PM number limit specified for diesel vehicles in UN R83/06;

• does not require compliance with the In Use Performance Ratio for OBD systems in UN R83/06;

• does not require the NOx monitoring for petrol vehicles specified in UN R83/06; and

• only requires flex fuel vehicles to meet the Type VI test when tested on petrol (details of requirements for flex fuel vehicles to meet the Type VI test under ADR 79/04 and ADR 79/05 at low temperature to be determined by 31 December 2011.)

*** Separate Non Methane Hydrocarbon (NMHC) limits only apply from Euro 5 onwards.

**** PM mass limits apply from Euro 5 onwards to petrol vehicles with direct injection engines.

“NA” means no limit applies.

To find the ADRs (except those prior to ADR79/00 which are now obsolete) on the Federal Register of Legislative Instruments (FRLI) follow these steps:

  1. Go to www.frli.gov.au
  2. In the “Browse for” list, choose “Legislative Instruments – As made – by title”.
  3. Wait for the alphabetical list to come up, scroll down to “V” and then click on “Ve” (for Vehicle).

The ADRs will be listed on the screen and you can open each of them individually to get the details.

ADR 79/05 will be formally determined by the Minister when UN Regulation 83 has been amended to incorporate the Euro 6 standards.

 

Emission Limits for Light Vehicles (≤ 3.5t GVM) under UN Regulations 83/.. at Euro 2, 3, 4, 5 & 6 levels

Reference mass
(RW)
(kg)
Limit Values (g/km)
Mass of carbon monoxide (CO) Mass of hydrocarbons
[Total and non-methane]
(THC)
(NMHC) (6)
Mass of oxides of nitrogen
(NOx)
Combined mass of total hydrocarbons and oxides of nitrogen
(THC+NOx)
Mass of particulates (1)
(PM)
Category Class Petrol Diesel Petrol Diesel Petrol Diesel Petrol Diesel Diesel (5)
Euro2 M (2) All 2.2 1.0 - - - - 0.5 0.7 0.08
Euro2 N1 (3) I RW ≤ 1250 2.2 1.0 - - - - 0.5 0.7 0.08
Euro2 N1 (3) II 1250 < RW ≤ 1700 4.0 1.25 - - - - 0.6 1.0 0.12
Euro2 N1 (3) III 1700 < RW 5.0 1.5 - - - - 0.7 1.2 0.17
Euro3 M (2) All 2.3 0.64 0.20 - 0.15 0.50 - 0.56 0.05
Euro3 N1 (3) I RW ≤ 1305 2.3 0.64 0.20 - 0.15 0.50 - 0.56 0.05
Euro3 N1 (3) II 1305 < RW ≤ 1760 4.17 0.80 0.25 - 0.18 0.65 - 0.72 0.07
Euro3 N1 (3) III 1760 < RW 5.22 0.95 0.29 - 0.21 0.78 - 0.86 0.10
Euro4 M (2) All 1.0 0.50 0.10 - 0.08 0.25 - 0.30 0.025
Euro4 N1 (3) I RW ≤ 1305 1.0 0.50 0.10 - 0.08 0.25 - 0.30 0.025
Euro4 N1 (3) II 1305 < RW ≤ 1760 1.81 0.63 0.13 - 0.10 0.33 - 0.39 0.04
Euro4 N1 (3) III 1760 < RW 2.27 0.74 0.16 - 0.11 0.39 - 0.46 0.06
Euro5 (4) M All 1.0 0.50 0.10
(0.068)
- 0.06 0.18 - 0.23 0.0045
Euro5 (4) N1 I RW ≤ 1305 1.0 0.50 0.10
(0.068)
- 0.06 0.18 - 0.23 0.0045
Euro5 (4) II 1305 < RW ≤ 1760 1.81 0.63 0.13
(0.09)
- 0.075 0.235 - 0.295 0.0045
Euro5 (4) III 1760 < RW 2.27 0.74 0.16
(0.108)
- 0.082 0.28 - 0.35 0.0045
Euro6 (4) M All 1.0 0.50 0.10
(0.068)
- 0.06 0.08 - 0.17 0.0045
Euro6 (4) N1 I RW ≤ 1305 1.0 0.50 0.10
(0.068)
- 0.06 0.08 - 0.17 0.0045
Euro6 (4) II 1305 < RW ≤ 1760 1.81 0.63 0.13
(0.09)
- 0.075 0.105 - 0.195 0.0045
Euro6 (4) III 1760 < RW 2.27 0.74 0.16
(0.108)
- 0.082 0.125 - 0.215 0.0045

(1) For compression ignition (diesel) engines only
(2) Except Category M vehicles of which the maximum mass exceeds 2,500 kg. For ADR79/00 (Euro 2) only, category M vehicles with more than 6 seats are also covered by the N category
(3) And those Category M vehicles which are specified in note (2)
(4) A particle number standard of 6.0 x 1011 particles/km will apply to diesel vehicles from Euro 5 onwards
(5) PM mass limits also apply from Euro 5 onwards to petrol vehicles with direct injection engines
(6) Separate NMHC limits only apply from Euro 5 onwards

What is so good about Zetti Cats & DPFs?

What is so good about Zetti Cats & DPFs?

Zetti means quality and that’s what we sell

Our Catalytic Converters are made to the highest quality standards and fit the first time, every time. Our range of European direct fit Catalytic Converters meet strict EURO emissions standards. This will ensure correct fitment and legal requirements are met all with minimal cost compared to factory items.

Made from the right stuff

palladium-rhodium-platinum

The use of precious metals is crucial to producing superior results and by combining Palladium, Rhodium and Platinum to form the composition of the substrate. These precious metals are fixed to the monolith via a Ceria based wash coat. All of the materials used are of high quality and have been tested to ensure product enhancement and ongoing range development.

How they compare

• 1.5mm stainless steel outer shell (opposed to 1.2mm found on others)

• Robot welding process

• 6mm matting compressed to 3mm

• Type Approved replacement parts

• Latest technology wash coat

• OBDII compliance

• Each Catalytic Converter is tested to 30Kpa

• Long service life – 80,000 to 160,000km*

• Product is Warranted

• Packaged for Catalyst protection

• Extensive range

Our EURO range covers all of your needs.
With a comprehensive listing of direct fit, Euro Catalytic Converters and DPF’s, Zetti really is the better choice when it comes to aftermarket replacement.

*Under normal driving conditions.

Zetti’s extensive range of Cats

underFloor-closeCoupled-manifold

Zetti’s massive range has got you covered

We stock a huge range of Manifold, Close Coupled and Under Floor Catalytic Converters with over 2,000 applications covering Australian, European, American and Asian vehicles. We really do have you covered when it comes to Emissions Control Systems.

What is a Catalytic Converter and What to know when replacing.

What is a Catalytic Converter & How does it work?

Introduced to Australian motor vehicles in 1986, Catalytic Converters were fitted to unleaded petrol vehicles to clean up the noxious exhaust gases produced during operation. The role of the Catalytic Converter is to control the harmful emissions from the combustion process by converting the Hydrocarbons (HC), Nitrogen Oxides (NOx) and Carbon Monoxide (CO) into Carbon Dioxide (CO2), Nitrogen (N2) and Water Vapour (H2O).

cat-diagram

The Catalytic Converter is designed to last the lifetime of the vehicle, but this is not always the case.** The premature failure of the Catalytic Converter could be attributed to poor tuning of the vehicles ignition, not servicing the vehicle at regular intervals, road impact damage, driving through deep water or using non-compatible fuels and additives. These conditions need to be avoided by the owner of the vehicle.

* Not all cats are designed with heat shields.
** Different materials used in the manufacturers construction process may attribute to shorter life span of the cat.

Replacing the Catalytic Converter… What you need to know.

1 – Ensure any engine or emission faults are rectified before replacing the catalytic converter. Failure to correct a pre-existing emissions problem could result in a damaged catalytic converter.

2 – It is recommended to replace the Oxygen Sensor when the Catalytic Converter is replaced. For correct operation of the engine and Catalytic Converter, the vehicle must be fitted with an Oxygen Sensor. When combustion gases are flowing through the exhaust, they are picked up by the Oxygen Sensor and a signal is sent back to the ECU. This signal then helps to control the air/fuel mixture entering the combustion chambers for a better ‘burn’.

gasket-stud-nut-oxysensor

3 – Always use new mountings, gaskets and bolts to avoid leakage or fitment issues. This will ensure the correct fitment first time around. Always recommend new studs, bolts and nuts when replacing any part of the exhaust system.

4 – When replacing a Catalytic Converter it is essential to examine the complete exhaust system from the manifold to the tail pipe for damage, corrosion or leaking/blowing. Repair or replace as required. A simple test is to have the vehicle running at idle whilst on the hoist. Use a shop rag to block the tailpipe (without burning your hand) and listen for any exhaust leaks in the system. Two people will be required for a closer inspection of any joins/pipes. The use of a vapour or smoke machine will accuarately locate any exhaust leaks.

5 – After replacing the cat converter be sure to run the vehicle at 2500rpm until the electric fans kick in. Then run the vehicle for a further 1 minute until the new catalytic converter temperature reaches 350˚C to ensure it is lighting off and functioning properly .

6 – Do not use exhaust sealant upstream of the Catalytic Converter. This can be a fatal move when working on the exhaust system. Sealants can contain ingredients that will harm the operation of the Catalytic Converter and also damage the Oxygen Sensor.