Mazda RX7. Manual - part 111

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 16)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 18: Location of Drain Hole No. 2

11. Pour all the pellets from the plastic bag containing a
smaller amount of pellets (0.6 L) into the drain hole No. 2.
See Fig. 19.

NOTE: Do not forget that the remaining space (0.8L) in the rear of
converter must later be filled with old pellets (see Fig. 19)
from the converter removed from the customer's vehicle as
described in Section IV-B, Step 8 through 11 below.

Fig. 19: Distribution of New and Old Pellets in Converter

12. Tighten the drain plug No. 2 temporarily.

B. Replacement of the Catalytic Converter

Following the procedure explained below,

i. remove the catalytic converter from the customer's vehicle,
ii. fill up the remaining space of the exchange converter with
the old pellets removed from the customer's converter, and
iii. install the exchange converter on the customer's vehicle.

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 17)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

CAUTION: * Allow the exhaust system to cool to avoid injury.
* Do not use air tool (impact wrenches) for loosening,
because it may result in breakage of the bolt or stud.
* Lubricate the threads with penetrating oil before
loosening the bolts and nuts to prevent them from
breaking.

1. Lift the vehicle on a hoist.
2. Disconnect the split air pipe from the pellet converter.
3. Remove the catalytic converter lower cover (protector No. 2).
See Fig. 20.

Fig. 20: Location of Protector No. 2

4. Remove the silencer hangers. See Fig. 21.

Fig. 21: Removing Silencer Hangers

5. Bend the tip of the exhaust pipe lower cover (protector No.4)

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 18)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

by using pliers in order to get the space for loosening the
catalytic converter nuts. See Fig. 22.

CAUTION: Be careful not to cut your fingers on the edge of the
lower cover.

Fig. 22: Bending Back Tip of Exhaust Pipe Lowe Cover

6. Loosen the four nuts connecting the catalytic converter to
the exhaust pipe and the monolith converter.

CAUTION: Lubricate the threads with penetrating oil before
loosening the nuts to prevent the stud bolts from
breaking. Breaking these studs would preclude re-use
of the converter housing.

7. Remove the catalytic converter, pushing the exhaust pipe
backward. See Fig. 23.

CATALYST PELLETS & MODIFICATION OF SECONDARY AIR SYS

Article Text (p. 19)

1983 Mazda RX7

For www.iluvmyrx7.com

Saturday, September 08, 2001 09:59AM

Fig. 23: Removing Catalytic Converter

8. Hold the removed converter level and securely in a vise as
shown in Fig. 17. Remove the drain plug No. 2 (rear) and
loosen the drain plug No. 1 (front) as shown in Fig. 14.

CAUTION: * Do not overtighten the vise.
* Do not remove the drain plug No. 1. Loosen only.

9. Remove the converter from the vise and remove all pellets
from the rear of converter by shaking the converter over a
clean pan that will catch the pellets.
10. Pour the pellets removed at Step 9 into the rear compartment
(drain hole No. 2) of the previously-prepared exchange
converter until it is full. Use the same procedure to fill
up as described in Sec. IV-A.

NOTE: If the old pellets removed from the rear compartment are
not enough to fill the rear compartment of the exchange
converter, use old pellets from the front compartment
(drain hole No. 1) of the removed converter.

11. Install a new lock washer and tighten the drain plug No. 2
of the exchange convener to the specified torque and bend
the lock washer to prevent the plug from loosening. See
Fig. 24.

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

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