Horrific MPG after new catalytic converter and O2 sensors

mikehkk

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Oct 17, 2018
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Location
Alameda, CA
Hello,

I'm the original owner of a '99 TJ Wrangler, with a 4.0 engine and 5-speed AX15 transmission. For the first few years after I bought it, it got about 18 MPG (highway or city, didn't seem to matter). Then for many years after that, it settled-in to a little less than that. 17.5, 17.6 MPG became the norm and it was very consistent that way. During those years I replaced the O2 sensors a few times, but not with OEM sensors. I used a Bosch brand. That didn't have any impact on MPG: the car continued to stay at 17.5/17.6 MPG. At one point I tried some of those 4-hole Bosch fuel injectors, to see if the vendors' claims about improved fuel economy were true. No, they weren't at all: but the MPG stayed exactly the same anyway (wasn't worse). At the 392,000 miles mark for the original engine - still going strong by-the-way, but destroyed as a result of the dealership's negligence - I put a remanufactured JASPER engine in. MPG was STILL exactly the same after that installation (17.5/17.6).

Beginning about four years ago, the MPG started gradually declining... 16... then 15, where it remained for the last two years. I know, I know, it's a JEEP, what should I expect? We don't buy them for their fantastic gas mileage of course. But I always thought it was odd. This last year, my jeep wouldn't pass smog for the first time ever (high "NOX", which I assume refers to nitrogen oxides). First, I had the mechanic install a new CA/CARB-compliant cat converter (I'm in CA as you've guessed). My car still failed the NOX test. We then installed OEM MOPAR O2 sensors. My car did pass CA smog at that point. My mechanic had a theory that the old original cat converter became clogged & dirty over time and that - along with the aftermarket O2 sensors may have been the cause of the MPG decline. A theory anyway...

Since I've been driving the car since the converter & OEM O2 sensor replacements, it's been getting even WORSE MPG. It's now only 12 MPG.

Anyone ever heard of a similar type experience? Is it possible that this is a temporary phenomenon as the car's computer adjusts to the new sensors and cat converter?

Really appreciate anyone's thoughts and ideas.

Thanks very much.
 
Last edited:
Exhaust leak or cracked header can fool the o2 into making it run rich. Compression and leakdown tests for engine health wouldn't be a bad idea. Just a couple things to do. Proper diagnosis with a good scanner and someone familiar with jeeps is important
 
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Exhaust leak or cracked header can fool the o2 into making it run rich. Compression and leakdown tests for engine health wouldn't be a bad idea. Just a couple things to do. Proper diagnosis with a good scanner and someone familiar with jeeps is important

Hi, thanks for reply. Exhaust header is new Banks I installed less than six months ago. My mechanic also checked for vacuum/exhaust leaks throughout. Was pretty thorough. Found none of either type. Compression was pretty good (and consistent) the last time I checked it (about a year ago). Am curious... what is a 'leakdown' test?
 
Hello,

I'm the original owner of a '99 TJ Wrangler, with a 4.0 engine and 5-speed AX15 transmission. For the first few years after I bought it, it got about 18 MPG (highway or city, didn't seem to matter). Then for many years after that, it settled-in to a little less than that. 17.5, 17.6 MPG became the norm and it was very consistent that way. During those years I replaced the O2 sensors a few times, but not with OEM sensors. I used a Bosch brand. That didn't have any impact on MPG: the car continued to stay at 17.5/17.6 MPG. At one point I tried some of those 4-hole Bosch fuel injectors, to see if the vendors' claims about improved fuel economy were true. No, they weren't at all: but the MPG stayed exactly the same anyway (wasn't worse). At the 392,000 miles mark for the original engine - still going strong by-the-way, but destroyed as a result of the dealership's negligence - I put a remanufactured JASPER engine in. MPG was STILL exactly the same after that installation (17.5/17.6).

Beginning about four years ago, the MPG started gradually declining... 16... then 15, where it remained for the last two years. I know, I know, it's a JEEP, what should I expect? We don't buy them for their fantastic gas mileage of course. But I always thought it was odd. This last year, my jeep wouldn't pass smog for the first time ever (high "NOX", which I assume refers to nitrogen oxides). First, I had the mechanic install a new CA/CARB-compliant cat converter (I'm in CA as you've guessed). My car still failed the NOX test. We then installed OEM MOPAR O2 sensors. My car did pass CA smog at that point. My mechanic had a theory that the old original cat converted became clogged & dirty over time and that - along with the aftermarket O2 sensors may have been the cause of the MPG decline. A theory anyway...

Since I've been driving the car since the converter & OEM O2 sensor replacements, it's been getting even WORSE MPG. It's now only 12 MPG.

Anyone ever heard of a similar type experience? Is it possible that this is a temporary phenomenon as the car's computer adjusts to the new sensors and cat converter?

Really appreciate anyone's thoughts and ideas.

Thanks very much.

A good scan tool that can read the long and short term fuel trims would be a good place for your mechanic to start.
Any chance of other forces effecting your mileage? Dragging brakes, bad bearings, etc?
I know my 99 has a cracked exhaust "header" but seems to quiet down after warm up.
Of course I have to get an E-test this morning , and started thinking of all the things that could go wrong. :rolleyes:
I hope someone has helpful insight for you !
 
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A good scan tool that can read the long and short term fuel trims would be a good place for your mechanic to start.
Any chance of other forces effecting your mileage? Dragging brakes, bad bearings, etc?
I know my 99 has a cracked exhaust "header" but seems to quiet down after warm up.
Of course I have to get an E-test this morning , and started thinking of all the things that could go wrong. :rolleyes:
I hope someone has helpful insight for you !

Good idea. If the poor mileage keeps up for long, I'll definitely be taking it back to the garage for a good scan. I know my mechanic is very well equipped that way too.
 
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I know my 99 has a cracked exhaust "header" but seems to quiet down after warm up.
Of course I have to get an E-test this morning , and started thinking of all the things that could go wrong. :rolleyes:

My 97 failed last summer for high Nox levels. My manifold has a pretty large crack in it which I think was causing it to run lean. I JB welded it with the extreme heat version and ran a bottle of cleaner thru it. Went from 2.9 to 2.4 GPM.
 
My 97 failed last summer for high Nox levels. My manifold has a pretty large crack in it which I think was causing it to run lean. I JB welded it with the extreme heat version and ran a bottle of cleaner thru it. Went from 2.9 to 2.4 GPM.

Thankfully my 99 past the E-test great.
Readings Limits

HC GPM 0.1285 .8000
CO GPM 2.2626 15.0000
CO2 GPM 578.62
NOx GPM 0.7622 1.5000

I am happy with the results , The TJ has 173704 on it.
 
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Bosch O2 sensors are well known to eventually cause problems in our Wrangler engines. There are only three that work correctly and well long-term NTK, NGK, and Mopar. All three are made by NTK and is the OEM the factory installs into all new Jeeps.