Catalytic Converter - 2.0L Zetec, 2.3L
Catalytic Converter - 2.0L and 2.3LSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Release the fuel system pressure. For additional information, refer to Fuel Delivery and Air Induction.
3. Remove and discard the catalytic converter-to-flex pipe flange nuts.
4. NOTE: When installing the catalytic converter, install a new gasket.
Remove and discard the catalytic converter-to-flex pipe assembly gasket.
5. Remove the 4 catalytic converter-to-engine bracket bolts and remove the bracket.
6. Remove the 2 retainer bolts and the 7 screws, then separate the lower heat shield from the upper heat shield.
7. NOTE: It may be necessary to reposition the engine during catalytic converter removal.
Remove the roll restrictor bolt.
8. Disconnect the catalyst monitor sensor and heated oxygen sensor (HO2S) electrical connectors.
9. Remove the upper heat shield bolts.
10. Disconnect the fuel tubes and the evaporative emission (EVAP) canister purge valve electrical connector.
11. Disconnect the other end of the upper fuel tube and remove the fuel tube.
12. Remove the EVAP canister purge valve bracket bolts and position the EVAP canister purge valve and bracket aside.
13. Remove and discard the 7 catalytic converter-to-cylinder head nuts and studs.
14. Remove the bolt and the engine lifting eye.
15. Remove the valve cover.
^ Using shop towels, cover the cylinder head.
16. NOTE: An assistant will be needed to remove the exhaust manifold and catalytic converter assembly and heat shield from the vehicle. Do not let the catalytic converter or the heat shield come in contact with the cylinder head.
Reposition the engine and carefully pull the exhaust manifold and catalytic converter assembly and shield upward. Roll the shield off, toward the RH side of the vehicle. Remove the exhaust manifold and catalytic converter assembly from the vehicle.
^ Discard the gasket.
17. NOTE: If installing a new converter, remove the catalyst monitor sensors.
Remove the 2 HO2S and the catalyst monitor.
Installation
1. NOTE: If installing a new converter, install the 2 HO2S and catalyst monitor sensors.
Install the 2 HO2S and the catalyst monitor.
^ Tighten to 47 Nm (35 ft. lbs.).
2. NOTE: An assistant will be needed to install the exhaust manifold and catalytic converter assembly and heat shield in the vehicle. Do not let the catalytic converter or the heat shield come in contact with the cylinder head.
Reposition the engine and carefully lower the exhaust manifold and catalytic converter assembly and shield downward. Roll the shield on, toward the LH side of the vehicle. Position the exhaust gasket and exhaust manifold and catalytic converter assembly in the vehicle.
3. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor before installation.
NOTE: Clean the mating surfaces of the exhaust manifold and the catalytic converter mating surfaces.
NOTE: Always install new fasteners and gaskets.
NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.
Using a straightedge and feeler gauge, place the straightedge across the catalytic converter flange surface and check for warpage with the feeler gauge. If the reading is greater than 0.76 mm (0.0295 inch), install a new catalytic converter, gasket and nuts.
Tighten the 7 new catalytic converter-to-cylinder head nuts and studs to 55 Nm (41 ft. lbs.) in the sequence shown.
4. Install the valve cover.
5. Install the engine lifting eyelet and the bolt.
^ Tighten to 45 Nm (33 ft. lbs.).
6. Reposition the EVAP canister purge valve and bracket and install the bolts.
^ Tighten to 6 Nm (53 inch lbs.).
7. Install and connect the upper fuel tube.
8. Connect the fuel tubes and the EVAP canister purge valve electrical connector.
9. Install the upper heat shield bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
10. Connect the HO2S electrical connector.
11. Connect the HO2S and catalyst monitor electrical connectors.
12. Install the roll restrictor bolt.
^ Tighten to 48 Nm (35 ft. lbs.).
13. Position the upper heat shield to the lower heat shield and install the 7 screws and the 2 retainer bolts.
^ Tighten to 11 Nm (8 ft. lbs.).
14. Install the catalytic converter-to-engine bracket and install the 4 bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
15. NOTE: When installing the catalytic converter, install a new gasket.
Install a new catalytic converter-to-flex pipe assembly gasket.
16. Install the new catalytic converter-to-flex pipe flange nuts.
^ Tighten to 47 Nm (35 ft. lbs.).