P0420 Code Explanation and Diagnosis for 2003 Honda S2000 with New Catalytic Converter
I recently installed a new catalytic converter and mufflers on my 2003 Honda S2000, both completed in early this week. On Sunday afternoon, the check engine light activated. I took the vehicle to Autozone for diagnostics, where they detected a P0420 code — Catalyst System Efficiency Below Threshold (Bank 1). They suggested that this could be related to the newly installed catalytic converter and advised resetting the warning light, expecting it would not reappear. However, within a few hours, the check engine light came back on. I visited my muffler shop to inspect the catalytic converter, and they confirmed it is functioning — one side registers approximately 180°F and the other around 300–320°F. Typically, healthy converters show temperature differences of about 300°F on one side and up to 450°F on the other. This issue has never occurred before, so I believe it is directly tied to the new converter installation. The mufflers were installed only Monday, so they are not likely the root cause. While there is a noticeable temperature differential indicating the converter is active, the overall temperatures are lower than expected. I'm seeking advice on what steps I should take next to resolve this issue. Could it be related to oxygen sensor performance or an exhaust leak? What diagnostic tools or procedures would you recommend for identifying and fixing this problem?
Check the upstream and downstream O2 sensors, as well as inspect for any exhaust leaks near the oxygen sensor locations. A faulty sensor or leak can cause misreading of catalytic converter efficiency.