Walker CalCat CARB 84719 Universal Catalytic Converter User Manual

1. Introduction and Product Overview

This manual provides essential information for the proper installation, operation, and maintenance of your Walker CalCat CARB 84719 Universal Catalytic Converter. This product is designed, tested, and validated to meet CARB standards, ensuring compliance for OBDII (1996 and newer) and non-OBD (1995 and older) vehicles.

The Walker CalCat converter features superior technology with an optimal high-technology washcoat for performance, consistent emissions compliance through a precise OE-style coating process, and a durable stainless-steel body with aluminized pipe and heat shields. Its flexible design includes expandable bushings for adaptable fitment.

Image 1.1: The Walker CalCat CARB 84719 Universal Catalytic Converter, showing its robust construction and identification markings.

Image 1.2: Official CARB Compliant logo, indicating the converter meets California Air Resources Board standards for emissions.

2. Safety Information

Installation of automotive exhaust components can be hazardous. Always follow these safety precautions:

• Ensure the vehicle is securely supported on jack stands or a lift before working underneath. Never rely solely on a jack.
• Allow the exhaust system to cool completely before beginning work to prevent burns.
• Wear appropriate personal protective equipment (PPE), including safety glasses, gloves, and hearing protection.
• Work in a well-ventilated area to avoid inhaling exhaust fumes or welding fumes.
• Disconnect the vehicle's battery before performing any electrical work.
• If welding is required, ensure proper fire safety measures are in place and use appropriate welding safety gear.
• Consult a professional mechanic if you are unsure about any step of the installation process.

3. What's in the Box

Upon opening the packaging, verify that all components are present and undamaged:

• One (1) Walker CalCat CARB Universal Catalytic Converter (Model 84719)

Note: Additional hardware such as gaskets, bolts, or clamps may be required for installation and are typically sold separately.

4. Product Specifications

5. Installation Guidelines

The Walker CalCat CARB 84719 is a universal catalytic converter designed for adaptable fitment. Installation typically requires specialized fabrication and/or welding. Professional installation by a certified mechanic is highly recommended.

5.1. Pre-Installation Steps

1. Vehicle Preparation: Park the vehicle on a level surface and engage the parking brake. Allow the exhaust system to cool completely.
2. Lift Vehicle: Safely raise the vehicle using a hydraulic lift or sturdy jack stands.
3. Inspect Existing System: Examine the current exhaust system for any damage, leaks, or worn components that may need replacement.
4. Measure and Plan: Carefully measure the space available and compare it to the dimensions of the new converter. Plan the cutting and welding points.

Image 5.1: A mechanic inspecting the vehicle's undercarriage, preparing for the installation of an exhaust component.

5.2. Removal of Old Converter (if applicable)

1. Locate the existing catalytic converter.
2. Remove any oxygen sensors connected to the converter.
3. Carefully cut or unbolt the old converter from the exhaust pipes. Be prepared for potential rust and seized fasteners.

5.3. New Converter Installation

1. Positioning: Position the new Walker CalCat converter in the desired location. The universal design with expandable bushings allows for flexibility.
2. Cutting and Fitting: Cut the existing exhaust pipes to match the length and angle required for the new converter. Ensure a snug fit.
3. Welding/Clamping: Securely weld or clamp the converter into place. If welding, ensure strong, leak-free seams.
4. Sensor Reinstallation: Reinstall any oxygen sensors into the new converter or adjacent exhaust pipes as per vehicle specifications.
5. Leak Check: After installation, start the engine and check for any exhaust leaks. Address any leaks immediately.

Image 5.2: A mechanic carefully positioning and installing a new exhaust component, demonstrating the hands-on nature of the process.

Image 5.3: A close-up of welding work on an exhaust component, highlighting the customizable fit aspect of the converter.

Image 5.4: Detailed view of exhaust flanges, which are critical for secure and leak-free connections in the exhaust system.

6. Operation and Function

A catalytic converter is an emissions control device that converts toxic pollutants in exhaust gas from an internal combustion engine into less toxic pollutants by catalyzing redox reactions. The Walker CalCat CARB 84719 utilizes a precise OE-style coating process to apply catalyst material to the substrate, ensuring consistent performance for assured emissions compliance.

This converter is designed to operate immediately upon installation, with no break-in period required. Its application-specific converter shell design and mat compression contribute to its readiness for operation.

Image 6.1: The catalytic converter shell, emphasizing that no break-in period is needed for immediate operation.

7. Maintenance

Catalytic converters are generally maintenance-free components. However, their longevity and efficiency are directly tied to the overall health of your vehicle's engine and exhaust system.

• Regular Engine Maintenance: Ensure your engine is properly tuned, and perform regular oil changes and spark plug replacements. A poorly running engine can send unburnt fuel to the converter, causing it to overheat and fail prematurely.
• Check for Leaks: Periodically inspect the exhaust system for any leaks, especially around the converter and its connections. Leaks can affect sensor readings and converter efficiency.
• Address Warning Lights: If the "Check Engine" light illuminates, have the vehicle diagnosed promptly. Issues indicated by this light, such as misfires or rich fuel mixtures, can damage the catalytic converter.
• Avoid Contaminants: Prevent engine coolants, oil, or other fluids from entering the exhaust system, as these can contaminate the catalyst material.

8. Troubleshooting

If you experience issues after installing your catalytic converter, consider the following common problems and solutions:

• "Check Engine" Light On:
  • Cause: Often related to oxygen sensor readings or catalytic converter efficiency below threshold.
  • Solution: Have the vehicle scanned for diagnostic trouble codes (DTCs). Ensure oxygen sensors are correctly installed and functioning. Verify there are no exhaust leaks.
• Rattling Noise from Exhaust:
  • Cause: May indicate a loose heat shield or a broken internal substrate within the converter.
  • Solution: Inspect heat shields for loose fasteners. If the noise is internal, the converter may be damaged and require replacement.
• Reduced Engine Performance or Power:
  • Cause: A clogged or restricted catalytic converter can impede exhaust flow.
  • Solution: This typically requires professional diagnosis to confirm a clogged converter. If confirmed, replacement is necessary.
• Strong Exhaust Odor:
  • Cause: An inefficient converter or an exhaust leak.
  • Solution: Check for exhaust leaks. If no leaks are found, the converter may not be functioning optimally and might need inspection or replacement.

For persistent issues, consult a qualified automotive technician.

9. Warranty and Support

Walker products are manufactured to high standards and are backed by a manufacturer's warranty. For specific warranty details, including coverage period and terms, please refer to the documentation provided with your purchase or visit the official Walker website.

For technical support, installation assistance, or warranty claims, please contact Walker customer service:

• Website: www.walkerexhaust.com
• Customer Service: Refer to the contact section on the official website for phone numbers or email support.

Please have your product model number (84719) and purchase information ready when contacting support.