Catalyst Replacement
- Raise vehicle on hoist. Attach vacuum aspirator device (J-25077) to exhaust pipe. See Fig 2 . Attach air supply to air hose fitting on vacuum pump. Apply enough air pressure (minimum 80 psi) to hold catalytic beads in place.
- Drive a small chisel between fill plug and converter housing, making sure not to damage housing. Continue driving small chisel into plug until plug is deformed enough to be removed with pliers.CAUTION: DO NOT pry plug from converter housing or damage to housing may result.
- Clamp vibrator and catalytic container onto converter. See Fig 2 . Disconnect air supply from vacuum aspirator and attach it to vibrator unit. Allow vibrator to operate for about 10 minutes to remove all catalytic beads.
- When all catalytic material is removed, disconnect air supply and remove container from the converter. Discard catalytic beads. Fill container with approved replacement catalytic beads. Install a fill tube fixture to vibrator device.
- Attach air supply to both vibrator and aspirator. With container attached to fill tube, catalytic beads will begin to move into converter.
- When catalytic beads stop flowing, disconnect air supply to vibrator and note level of beads. It should be even with fill plug. Add more beads if required.NOTE: If any beads exit through tailpipe during refilling of converter, converter is defective and must be replaced.
- Apply a anti-seize compound to fill plug. Install plug and tighten. If equipped with a press type fill plug, install a "bridge-and-bolt" type service plug and tighten to 28 ft. lbs. (38 N.m).