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Mazda RX7. Manual - part 110

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 12)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 12: Blowing Chips off with Air Gun

9. Re-install the cap and switching valve removed in Step 6.
10. Re-install the check valve to the intake manifold.

CAUTION: Be sure to fit the check valve into the intake manifold.

NOTE: The check valve may fall out when ACV is removed. Be sure
to retrieve and set back in place before re-installing ACV.
See Fig. 13.

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 13)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 13: Check Valve Position and Orientation

11. Re-install the air control valve.

NOTE: If the gasket cannot be re-used, use new one provided in the
kit.

12. Reconnect the hoses and the hot air duct. Be sure to install
the clamps securely.

IV. Replacement of the Catalyst Pellets

A. Preparation of Exchange Container

As mentioned in Item E of attachment I, the exchange container
is to be partially prepared prior to initiation of the repair on
each individual vehicle. This section describes how to prepare
an exchange container.

CAUTION: * Wait until the catalytic converter has cooled.
* Use protective gloves and a prepared dust mask during
replacement of the pellets.

1. Remove the drain plug No. 1 and No. 2 of the empty catalytic
converter for exchange operation. See Fig. 14.

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 14)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 14: Location of Drain Plugs No. 1 and 2

2. Hold the converter in a vise at an angle of 25

-30

as shown

in Fig. 15.

Fig. 15: Proper Positioning of Converter in a Vise

3. Put the funnel provided in the drain hole No. 1 (front side).
4. Pour all the pellets from the plastic bag containing a larger
amount of pellets (1.4 L) into the drain hole No. 1.
5. Tap the converter repeatedly at point "A" (see Fig. 15) with
a plastic hammer to allow the pellets to flow in until no
more pellets can be put in.
6. Hold the converter level in the vise. See Fig. 16.

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 15)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 16: Converter in Level Position

7. Tap the converter repeatedly at points "A" and "B" until all
pellets are in.
8. Install a new lock washer and tighten the drain plug No. 1
to the specified torque. Torque to 30-50 N-m. Bend the lock
washer to prevent the plug from loosening. See Fig. 17.

Specified Torque: 30-50 N-m (22-36 ft-lb)

Fig. 17: Installing New Lock Washer on Converter

9. Hold the catalytic converter at an angle of 25

-30

in a vise

again (see Fig. 15).
10. Put the funnel in drain hole No. 2 (rear side). See Fig. 18.

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