Catalytic Converter - 2.3L PZEV Manifold: Removal

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.

NOTE: Always install new fasteners and gaskets. Clean flange faces prior to new gasket installation to make sure of proper sealing.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the generator air inlet duct.

Fig 1: Locating Generator Air Inlet Duct And Bolts
Courtesy of FORD MOTOR CO.
Disconnect the heated oxygen sensor (HO2S) and 2 catalyst monitor sensor (CMS) electrical connectors.
Remove the wiring harness bracket off the stud and position it aside.
Remove the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
- Discard the gasket and the 2 nuts.
Remove the 4 heat shield bolts and the heat shield.
Remove the 2 catalytic converter manifold shield bracket bolts and the bracket.
Loosen the 2 catalytic converter manifold bracket bolts.
Disconnect the secondary injection hose from the catalytic converter manifold.

Fig 2: Locating Secondary Injection Hose
Courtesy of FORD MOTOR CO.

NOTE: If installing a new catalytic converter manifold, remove the heated oxygen sensor (HO2S) and the catalyst monitor sensors for installation in the new catalytic converter manifold.

Fig 3: Identifying Special Oxygen Sensor Tool

Courtesy of FORD MOTOR CO.

Using the special tool, remove the HO2S and 2 CMS.
Remove the 7 catalytic converter manifold nuts and remove it from the vehicle.
- Discard the 7 nuts and the gasket.
Clean and inspect the manifold. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
Remove and discard the 7 catalytic converter manifold studs.