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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1821 (Exhaust System - F-150 & Mark LT) >> Removal And Installation >> Exhaust Y-Pipe - Dual Catalytic Converter >> Installation >> All engines

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WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Use caution installing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.
  1. Position the RH catalytic converter.


    NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
    NOTE: A special tool is available for use in installing the catalyst monitor sensor. An open-end wrench can be used for ease of installation.
  1. Install the RH catalyst monitor.
    • Tighten to 40 Nm (30 lb-ft).
  2. Loosely install the exhaust Y-pipe-dual catalytic converter hanger bracket and isolator and RH exhaust Y-pipe-dual catalytic converter hanger bracket and isolator bolt. Let the LH side of the exhaust Y-pipe-dual catalytic converter hanger bracket and isolator hang down.


    NOTE: Use caution installing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.

    Using an abrasive pad, clean the exhaust clamp surface area of any surface rust.

  1. Position the LH catalytic converter and loosely install the exhaust manifold nuts.
    2. NOTE: Make sure to apply anti-seize lubricant to the threads of the sensors before installation.
    NOTE: A special tool is available for use in installing the catalyst monitor sensor. An open-end wrench can be used for ease of installation.
  2. Install the LH catalyst monitor sensor.
    • Tighten to 40 Nm (30 lb-ft).


  1. Loosely install the bolt for the LH side of the exhaust Y-pipe-dual catalytic converter hanger bracket and isolator.
    2. NOTE: Use caution installing the catalytic converter. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs.
  2. Push the RH catalytic converter into place and loosely install the exhaust manifold nuts.
    3. NOTE: Using an abrasive pad, clean the exhaust coupling surface area of any surface rust.
    NOTE: Whenever the exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling is loosened, a new exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling must be installed.
  3. Loosely slide the exhaust Y-pipe-dual catalytic converter-to-exhaust intermediate pipe coupling into place.
    4. NOTE: 4.6L and 5.4L shown, 4.2L similar.
    Fig 1: Locating LH Catalytic Converter-To-Exhaust Manifold Joint Nuts
    GF0004189Courtesy of FORD MOTOR CO.
  4. Tighten the LH catalytic convert-to-exhaust manifold nuts in the following sequence.
    • Tighten the lower nut to 20 Nm (15 lb-ft).
    • Tighten the upper nut to 40 Nm (30 lb-ft).
    • Tighten the lower nut to 40 Nm (30 lb-ft).
    5. NOTE: 4.6L and 5.4L shown, 4.2L similar.
  5. Tighten the RH catalytic convert-to-exhaust manifold nuts in the following sequence.
    • Tighten the lower nut to 20 Nm (15 lb-ft).
    • Tighten the upper nut to 40 Nm (30 lb-ft).
    • Tighten the lower nut to 40 Nm (30 lb-ft).
    6. Fig 2: Locating RH Catalytic Converter-To-Exhaust Manifold Joint Nuts
    GF0004190Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH similar.
    Fig 3: Locating Heat Shield Bolts
    GF0004191Courtesy of FORD MOTOR CO.
  6. Tighten the heat shield bolts to the transmission crossmember.
    • Tighten to 15 Nm (11 lb-ft).


  1. Connect the 2 catalyst monitor sensor electrical connectors.
  2. If equipped, install the skid plate.
  3. Align the exhaust system and tighten the exhaust system clamps. For additional information, refer to Exhaust System Alignment  in this article.
    Fig 1: Locating Skid Plate
    GF0004171Courtesy of FORD MOTOR CO.
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