Originally Posted By: simple_gifts
Originally Posted By: Tegger
It's pretty much certainly the cat, especially if the vehicle has been driven repeatedly with a fuel-level below 1/4 tank.
What is the reasoning behind this?
Very low fuel results in intermittent starvation of the fuel pump, which in turn causes intermittent lean-misfires as fuel-pressure drops intermittently.
The misfires are not frequent enough for you or the ECM to feel (so no MIL), but they cause the cat's surface to overheat temporarily, which damages it. Over time the cat's surface erodes, reducing the cat's oxygen-storage capacity, and thus its life. It's a cumulative thing, much like smoking and emphysema.
At least some automakers put warnings in their Owner Manuals that proscribe driving around with low fuel levels, and this is why.