Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSPONTIAC19846000 STEREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMCATALYTIC CONVERTERSERVICE PROCEDURESCATALYST REPLACEMENT
1984 Pontiac 6000 STE
Catalyst Replacement
1984 Pontiac 6000 STESECTION Catalyst Replacement
- Raise vehicle on hoist. Attach vacuum aspirator device (J-25077) to exhaust pipe. See Fig 2 . Attach air supply to air hose fitting on vacuum pump. Apply enough air pressure (minimum 80 psi) to hold catalytic beads in place.
- Drive a small chisel between fill plug and converter housing, making sure not to damage housing. Continue driving small chisel into plug until plug is deformed enough to be removed with pliers.CAUTION: DO NOT pry plug from converter housing or damage to housing may result.
- Clamp vibrator and catalytic container onto converter. See Fig 2 . Disconnect air supply from vacuum aspirator and attach it to vibrator unit. Allow vibrator to operate for about 10 minutes to remove all catalytic beads.
- When all catalytic material is removed, disconnect air supply and remove container from converter. Discard catalytic beads. Fill container with approved replacement catalytic beads. Install a fill tube fixture to vibrator device.
- Attach air supply to both vibrator and aspirator. With container attached to fill tube, catalytic beads will begin to move into converter.
- When catalytic beads stop flowing, disconnect air supply to vibrator and note level of beads. It should be even with fill plug. Add more beads if required.NOTE: If any beads exit through tailpipe during refilling of converter, converter is defective and must be replaced.
- Apply a anti-seize compound to fill plug. Install plug and tighten. If equipped with a press type fill plug, install a "bridge-and-bolt" type service plug and tighten to 28 ft. lbs. (38 N.m).
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.