Service Procedure

1. Disconnect air supply pipe from catalytic converter.

2. Disconnect intermediate pipe from rear of converter.

3. Disconnect hanger bracket from converter, except Corvette.

4. On Corvettes, remove nuts and bolts and remove converter. All other models, remove front exhaust clamp then remove converter.

5. Stand old converter upright on inlet end and pour two (2) 8 ounce cups of water into outlet end to control catalyst dust.

FIGURE 1 - CONVERTER BELT FLANGE:

6. Using hammer and chisel, remove upper bed fill hole plug (see Figure 1 for description of upper and lower beds) from old converter by driving chisel between the converter shell and rim of fill plug. Deform fill plug until it can be removed with pliers.

7. Hold converter over a clean pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure 1) with rubber mallet.
NOTICE: If upper bed is void or near void (a cup or less) of catalyst beads, the converter is considered damaged (internally) or expanded. Catalyst beads found in internally damaged or expanded converters are not to be used in new converters. These beads can be returned via exchange program described in WDDGM Bulletin IB No. 80-93.

8. Pour upper bed beads into sifting pan J-34155-1. Sift out broken beads (smaller than half size) into a clean box. Pour sifted beads (half size and larger) into the other pan J-34155-2. Set sifted beads aside for now.

NOTICE: Unusable beads and dust can be returned via exchange program described in WDDGM Bulletin IB No. 80-93.

FIGURE 2 - CONVERTER BELT FLANGE:

9. Prop new converter up at a 45~ angle with upper bed fill hole at top. (See Figure 1 for a description of upper and lower beds.) Tap funnel J-34155-3 into converter fill hole with hammer (Figure 2).
10. Install packet of new upper bed beads from kit, P/N 25056590, into upper bed of the new converter.

FIGURE 3 - FULL CONVERTER:

11. Pour sifted upper bed beads (ref. Step 8) or new upper bed beads if required into upper bed of new converter. Tap belt flange of converter with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full. See Figure 3 for definition of full upper bed.

If upper bed is full, proceed to Step 12. If upper bed is not full, use leftover upper bed catalyst beads from involved dual bed converters to fill upper bed. If there are not enough used upper bed beads, obtain upper bed bead kit, P/N 25056680 (zone approval is required to obtain this kit), and continue to fill upper bed until full.

NOTICE: Used upper bed beads (from non-damaged or expanded converters) can be mixed with new upper bed beads. DO NOT MIX UPPER AND LOWER BEADS. Also, do not mix any other catalyst beads from converters other than converters involved in this bulletin. Store unused upper bed beads in a clean container marked "upper bed".

12. Lay converter down on a flat surface with upper bed on top.

13. Insert fill plug, P/N 8998202 (provided in kit, P/N 25056590), into upper bed fill hole. If outer rim of the fill plug doesn't fit flat against converter shell, remove enough beads so it does.

FIGURE 4 - FILL PLUG:

14. With fill plug in fill hole, insert tool J-34118 into fill plug (Figure 4). Tighten tool to 35 ft.lbs. (47 N-m) and make sure plug outer rim is flat and tight against converter shell. Set new converter aside.
15. Remove lower bed fill hole plug from old converter using procedure described in Step 6.

FIGURE 1 - CONVERTER BELT FLANGE:

16. Hold converter over a clean pan (J-34155-2) and empty catalyst beads by shaking and tapping converter belt flange (Figure 1) with rubber mallet.

FIGURE 1 - CONVERTER BELT FLANGE:

FIGURE 2 - CONVERTER BELT FLANGE:

17. Sift lower bed beads using procedure described in Step 8.

18. Prop new converter up at a 45~ angle with lower bed fill hole at top. (See Figure 1 for definition of upper and lower beds.) Tap funnel J-34155-3 into converter fill hole with hammer (Figure 2).

FIGURE 3 - FULL CONVERTER:

19. Pour sifted lower bed beads (ref. Step 17) or new lower bed beads if required, into new converter lower bed. Tap belt flange with rubber mallet to allow beads to settle. Continue filling and tapping until converter is full (ref. Figure 3).
If lower bed is not full, use leftover lower bed catalyst beads saved from involved dual bed converters to fill lower bed. If there are not enough used lower bed beads, obtain lower bed bead service kit, P/N 25056682 (zone approval is required to obtain this kit), and continue filling the lower bed until full.

NOTICE: The leftover lower bed beads can be saved for future use. Store them in a clean container marked "lower bed" DO NOT MIX UPPER AND LOWER BEADS, Also, do not mix any other catalyst beads from converters other than converters involved in this bulletin.

20. Lay converter down on flat surface with lower bed on top and install fill plug using procedure described in Steps 13 and 14.

21. Reverse removal procedure for installation of new converter. Refer to appropriate service manual for installation torque.

22. Lower vehicle.

Labor Operation Number: T0117

Labor Time : .9 hours