Funny you should reply to this today, as I have just heard back from a customer who recently (January) had a catalyst replaced under warranty at the place where he purchased the car.
11 months previously he had had the cat replaced & shortly afterwards the MIL had come on. He took it back & was assured that it was nothing to worry about. He came to me for a service in February (with the second cat fitted) & I again noted the P0420 code. I checked upstream & downstream O2 sensor activity & was happy with their performance (No scope required ). Short & long term fuel trims where very close to zero (idle & cruised throttle). I had previously updated the PCM software as a matter of course & advised him of the likelihood of the combat that would follow.
He approached the sales guy who fitted the previous cat & was told that he would change it, but the labour would have to be paid for. So again a new cat was fitted.
Within a couple of months, the MIL is back on & again P0420 is logged. I repeat my previous tests & supply the customer with IDS fuel trim & HEGO sensor graphs, plus emissions print-outs, showing RPM & Oil Temp. All the evidence was there. The cat was capable of passing an MOT (Just) & all vital statistics where good.
I provided an inoice stating that a quality catalyst would be required to cure the problem. The sales guy told him that the supplier had said that... "there must be a problem with the car"
Of course the driver is not in position to argue, or take the challenge. The only way to prove the case, is to fit a genuine unit. However, that's not really an option for most folks who choose the cheap route in the first place.
I suppose its a numbers game for the manufacturers.
For me, its dealer cats only, or take it elsewhere. I would sooner be twiddling my thumbs, than be creating a problem down the road.
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