Catalytic Converter - 2.3L PZEV Manifold: Installation
WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
- Inspect the catalytic converter manifold for warpage across the manifold flange area.
- Install the 7 new catalytic converter manifold studs.
- Tighten to 17 Nm (13 lb-ft).
- Position a new catalytic converter manifold gasket on the studs.
- Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2 stages.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).
- If installing a new converter, install the HO2S and the 2 CMS using the special tool.
- Tighten to 47 Nm (35 lb-ft).
- Connect the secondary injection hose to the catalytic converter manifold.
- Tighten the 2 catalytic converter manifold bracket bolts.
- Tighten to 20 Nm (15 lb-ft).
- Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
- Tighten to 20 Nm (15 lb-ft).
- Position the heat shield and install the 4 heat shield bolts.
- Tighten to 10 Nm (89 lb-in).
- Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
- Install a new gasket.
- Tighten to 40 Nm (30 lb-ft).
- Position the wiring harness bracket on the stud.
- Connect the HO2S and 2 CMS electrical connectors.
- Install the generator air inlet duct.
CAUTION:
If the warpage is greater than 0.76 mm (0.03 in), install a new catalytic converter manifold.
CAUTION:
Failure to tighten the catalytic converter manifold nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
CAUTION:
Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an exhaust leak.
NOTE:
Make sure to tighten the nuts in the sequence in 2 stages.
NOTE:
Apply anti-seize lubricant to the threads of the sensors before installation.