Catalytic Converter: Installation

NOTE: Failure to tighten the catalytic converter manifold fasteners in 20 Nm increments until reaching final torque of 55 Nm will cause the converter to develop an exhaust leak.

Fig 1: Identifying Catalytic Converter Assembly Bolt And Nuts Tightening Sequence

Courtesy of FORD MOTOR CO.

Install a new gasket, catalytic converter assembly and new fasteners. Tighten the bolt and 4 nuts in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 40 Nm (30 lb-ft).
- Stage 3: Tighten to 55 Nm (41 lb-ft).

NOTE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

Fig 2: Locating Catalytic Converter-To-Muffler And Tailpipe Assembly Nuts

Courtesy of FORD MOTOR CO.

Install a new gasket and 2 new catalytic converter-to-muffler and tailpipe assembly nuts.
- Attach the muffler and tailpipe assembly isolator.
- Tighten to 48 Nm (35 lb-ft).
Remove the cable ties, support wrap or suitable splint from the exhaust flexible pipe.

Fig 3: Supporting Exhaust Flexible Pipe With Support Wrap Or Suitable Splint
Courtesy of FORD MOTOR CO.
Install the catalytic converter bracket and the 4 bolts.
1. Tighten the 2 catalytic converter bracket-to-engine block bolts to 50 Nm (37 lb-ft).
2. Tighten the 2 catalytic converter bracket-to-catalytic converter bolts to 25 Nm (18 lb-ft).
Fig 4: Identifying Catalytic Converter Bracket And Bolts
Courtesy of FORD MOTOR CO.
Install the halfshaft support bracket and the 3 bolts.
1. Tighten the upper bolt to 48 Nm (35 lb-ft).
2. Tighten the 2 lower bolts to 24 Nm (18 lb-ft).
Fig 5: Identifying Halfshaft Support Bracket And Bolts
Courtesy of FORD MOTOR CO.
Install the RH halfshaft. For additional information, refer to Front Drive Halfshafts, Halfshaft - Exploded View in FRONT DRIVE HALFSHAFTS .
Install the Catalyst Monitor Sensor (CMS). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
Install the 4 bolts and the heat shield.
- Tighten to 10 Nm (89 lb-in).
Fig 6: Locating Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Install the Heated Oxygen Sensor (HO2S). For additional information, refer to ELECTRONIC ENGINE CONTROLS .
Fill the transmission/transaxle to the correct fluid level. For Automatic Transmission/Transaxle, refer to Transmission Fluid Level Check in AUTOMATIC SHIFTING MANUAL TRANSMISSION/TRANSAXLE . For Manual Transmission/Transaxle, refer to TRANSAXLE DRAINING AND FILLING .