Special Tools
A. Converter Bead Replacement Tool KitEach Buick dealer was shipped during March 1983, one (1) complete catalytic converter bead replacement tool kit J-34155, no charge. Each kit consists of:
J-34155-1 Sifting Pan (1)
J-34155-2 Storage Pans (2)
J-34155-3 Funnel (1)
In the event additional kits are required by the dealer, they may be purchased from:
Kent-Moore Tool Division Kent-Moore Corporation 29784 Little Mack Roseville, MI. 48066
CATALYTIC CONVERTER REPLACEMENT PROCEDURE
CAUTION: The catalytic converter beads contain platinum, palladium, and/or rhodium. Additionally, the beads may be finely coated with lead compounds. Therefore, precautions should be taken to minimize dust generation during the replacement procedure. These precautions include:
^ Catalyst dust should be controlled by wetting with water prior to bead removal, as described in Step 4.
^ The use of a suitable dust mask, rubber gloves, and safety glasses is recommended when handling catalyst beads.
^ Applicable OSHA standards should be reviewed.
^ Allow converter to cool before handling.
1. Loosen clamp and disconnect AIR pipe from converter.
2. Disconnect intermediate exhaust pipe and hanger from rear of converter.
3. Remove clamp and disconnect converter from front exhaust pipe.
4. Stand the old converter upright on the inlet end and pour 16 ounces of water into the outlet end to control catalyst dust..
FIGURE 1 - CATALYTIC CONVERTER:
5. Using a hammer and chisel, remove the fill hole plug from the lower bed (the smooth side of the converter is the lower bed side). See Figure 1.
6. Hold the converter over a clean pan (J-34155-2) and empty the catalyst beads by shaking.
It may be necessary to tap the converter belt flange with a hammer to loosen the beads.
7. Pour the beads into a sifting pan (J-34155-1) and sift to remove undersized beads.
8. Prop the new converter up at a 45-degree angle with the lower bed fill hole at the top.
FIGURE 1 - CATALYTIC CONVERTER:
9. Using funnel J-34155-3, pour the sifted beads into the lower bed of the new converter (see Figure 1). Tap belt flange with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. If additional beads are required to completely fill the lower bed, it will be necessary to obtain a lower bed bead kit from the parts department.
Excess beads from the kit should be saved in a clean container for future use.
10. Lay the converter down on a flat surface with the lower bed fill hole on top.
11. Insert the fill plug into the lower bed fill hole. The fill plug outer rim must rest against the converter body.
FIGURE 2 - INSTALLATION TOOL/TORQUE SPECIFICATION:
12. Insert tool J-34188 into fill plug and tighten to a torque 47 N-m (35 ft.lbs.). (see Figure 2).
13. Install new converter in vehicle reversing removal procedure (Steps 1, 2, and 3) and using new bolts and clamp as required. Torque front clamp nuts to 35 N-m (26 ft.lbs.), intermediate pipe to converter bolts to 20 N-m (15 ft.lbs.) and hanger to converter bolts to 52 N-m (38 ft.lbs.).
WARRANTY INFORMATION
Labor Trouble
Operation Number Hours Code
T5094 .9 hrs. 92
When submitting a warranty claim, the parts amount requested must reflect
an amount equal to only the portion of the lower bead package, part number 25056903, used for completing the repair when a complete bead package is not required. When only a portion of the bead package is used, a parts count of one (1) must be included in the total parts count entry.