Catalytic Converter: Service and Repair

Fig. 10 Vacuum pump installation:

Fig. 11 Vibrator tool installation:

Fig. 12 Filler plug replacement kit:

Note: The catalyst in the monolithic type converter is not replaceable. If it is determined that the converter has lost its effectiveness, it must be replaced.

1. Raise vehicle.
2. Connect hose of vacuum pump J-25077 on tailpipe and tighten clamp, Fig. 10.
3. Connect shop air to fitting on vacuum pump. Shop air must provide a minimum of 80 psi.
4. On early model converters, remove fill plug using a 3/4 inch allen wrench or tool J-25077-3. On later model converters, remove fill plug as follows:
a. Drive a small chisel between plug and converter housing. Use care to avoid damaging converter housing.
b. Continue to drive chisel into plug to deform it.
c. Repeat steps a and B at several locations around plug until it is deformed sufficiently to be removed with pliers. Do not pry on converter housing.
5. Position vibrator (part of tool J-25077) on converter and lock it in place, Fig. 11.
6. Disconnect air hose from vacuum pump and connect it to vibrator. Catalyst pellets will fall into can for about 10 minutes.
7. When converter is empty, disconnect air hose, remove can and discard pellets.
8. Install refill can on vibrator and connect air hose to vacuum pump attached to tailpipe. Pellets will be drawn into converter. If any pellets exit from the tailpipe, the converter housing is defective and must be replaced.
9. When converter is full, remove vibrator from converter.
10. On early model converters with threaded plug, coat plug threads with an anti-seize compound, then install plug and torque to 40 ft lbs. On later models with non-threaded plug, Fig. 12, proceed as follows:
a. Insert screw into bridge and position bridge inside filler plug opening.
b. Remove screw from bridge, being careful not to disturb position of bridge.
c. Insert screw through washer and plug, then thread screw into bridge and tighten.
11. Disconnect air hose from vacuum pump and remove vacuum pump.