Catalytic Converter: Installation

All vehicles 

1. Install the 7 new catalytic converter-to-cylinder head studs.
   • Tighten to 17 Nm (150 lb-in).
2. Position the new gasket on the engine.
3. NOTE: An assistant will be needed to install the catalytic converter and lower heat shield in the vehicle. Do not let the catalytic converter or the lower heat shield come in contact with the valve cover.

   Reposition the engine and carefully lower the catalytic converter and heat shield downward. Roll the heat shield toward the LH side of the vehicle and onto the catalytic converter.

   • Using 7 new nuts, install the catalytic converter onto the engine.
4. NOTE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak. Due to the possibility of the catalytic converter nuts loosening after the first tightening sequence, a second sequence (stage 2) will ensure that the catalytic converter nuts are properly torqued.

   Tighten the 7 new catalytic converter nuts in 2 stages in the sequence shown in the illustration.

   • Stage 1: Tighten to 55 Nm (41 lb-ft).
   • Stage 2: Tighten to 55 Nm (41 lb-ft).
   Fig 1: Catalytic Converter Nuts Tightening Sequence

   Courtesy of FORD MOTOR CO.
5. Install the engine lifting eyelet and the bolt.
   • Tighten to 45 Nm (33 lb-ft).
6. Reposition the EVAP canister purge valve bracket and install the 2 bolts.
   • Tighten to 6 Nm (53 lb-in).
7. Attach the fuel tube to the canister purge valve bracket.
8. Install the canister purge valve on the canister purge valve bracket.
9. Connect the EVAP canister purge valve electrical connector.
10. Install the EVAP canister purge valve heat shield and the 2 retainers.
11. Connect the HO2S and CMS electrical connectors.
12. Install the roll restrictor bolt.
    • Tighten to 70 Nm (52 lb-ft).
13. Position the lower heat shield and install the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
14. Install the catalytic converter-to-engine bracket and the 2 bolts.
    • Tighten to 47 Nm (35 lb-ft).
15. Install the 2 catalytic converter bracket-to-engine bracket bolts.
    • Tighten to 23 Nm (17 lb-ft).

    Non-PZEV 

16. Using a new gasket, attach the catalytic converter-to-muffler and tailpipe assembly and install the 2 new nuts.
    • Tighten to 47 Nm (35 lb-ft).

    PZEV 

17. Using a new gasket, attach the exhaust flexible pipe-to-muffler and tailpipe assembly and install the 2 new nuts.
    • Tighten to 47 Nm (35 lb-ft).

    All vehicles 

18. Remove the exhaust flexible pipe support wrap or suitable splint.
    Fig 2: Locating Exhaust Flexible Pipe Supported By Wrap Or Suitable Splint

    Courtesy of FORD MOTOR CO.
19. Install the upper heat shield and the 6 bolts.
    • Tighten to 11 Nm (97 lb-in).