Catalytic Converter: Service and Repair
Catalytic Converter-2.0L Zetec, 2.3L1. Relieve the fuel system pressure.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove and discard the catalytic converter-to-muffler flange nuts.
4. Remove and discard the catalytic converter-to-muffler gasket.
5. Remove the 4 bolts and the support bracket.
6. Remove the 2 retainer bolts and the 7 screws, then separate the lower heat shield from the upper heat shield
7. Disconnect the Catalyst Monitor Sensor (CMS) and Heated Oxygen Sensor (HO2S) electrical connectors.
8. Remove the bolts and the roll restrictor.
9. Lower the vehicle.
10. Disconnect the breather tube from the valve cover.
11. Remove the upper heat shield bolts.
12. Remove the Vapor Management Valve (VMV).
1 Disconnect the electrical connector.
2 Disconnect the upper fuel line.
3 Disconnect the lower fuel line.
13. Disconnect the other end of the upper fuel line and remove the fuel line.
14. Remove the bolts and the VMV bracket.
15. Position aside the power steering reservoir.
16. Remove and discard the 7 catalytic converter-to-cylinder head nuts.
17. Remove the bolt and the radio capacitor and bracket. Disconnect the electrical connector.
18. Remove the bolt and the engine lifting eye.
19. Remove and discard the catalytic converter gasket.
20. Remove the valve cover.
- Using shop towels, cover the cylinder head.
21. NOTE: An assistant will be needed to remove the catalytic converter and heat shield from the vehicle. Do not let the catalytic converter or the heat shield come in contact with the cylinder head.
Using a pry bar, move the engine forward. Carefully pull the catalytic converter and shield upward. Roll the shield off, towards the RH side of the vehicle. Remove the catalytic converter from the vehicle.