Catalytic Converter - Underbody: Installation
WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:
The exhaust hanger insulators are constructed of a special material. Use only the correct specification exhaust hanger insulator or damage to the exhaust system may occur.
NOTE:
Check the exhaust hanger insulators for damage and fatigue. Install new exhaust hanger insulators as required.
NOTE:
Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
- Install the service clamp onto the catalytic converter section.
- Install the catalytic converter section and service clamp onto the muffler section.
- Inspect the exhaust intermediate pipe/exhaust Y-pipe and resonator flange studs for damage.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).NOTE: If replacement of the exhaust intermediate pipe/exhaust Y-pipe flange stud(s) is required, perform Steps 4 and 5.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).
- Use the C-Frame and Screw Installer/Remover to push the 10-mm stud out of the flange.
- Use a C-clamp and a deep-well socket to push the 10-mm stud fully into the flange.
- Make sure the stud is fully and evenly seated into the flange.
NOTE: If replacement of the resonator flange stud(s) is required, perform Steps 6 and 7.
- Make sure the stud is fully and evenly seated into the flange.
- Use the C-Frame and Screw Installer/Remover to push the 8-mm stud out of the flange.
- Use a C-clamp and a deep-well socket to push the 8-mm stud fully into the flange.
- Make sure the stud is fully and evenly seated into the flange.
- Attach the catalytic converter and muffler assembly to the 3 exhaust hangers.
- Install a new resonator-to-muffler gasket by hand.
- Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
- Stage 3: Tighten to 17 Nm (150 lb-in).
- Install a new converter-to-exhaust intermediate/exhaust Y-pipe gasket by hand.
- Install the 2 new 10-mm catalytic converter-to-exhaust intermediate/exhaust Y-pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 25 Nm (18 lb-ft).
- Tighten the 4 service clamp nuts to 47 Nm (35 lb-ft).
NOTE:
Do not tighten the service clamp at this time.
NOTE:
When positioning the new 10-mm stud in the exhaust intermediate/exhaust Y-pipe flange, make sure to line up the new stud seat knurls with witness knurl grooves in the exhaust intermediate/exhaust Y-pipe flange.
NOTE:
When positioning the new 8-mm stud in the resonator flange, make sure to line up the new stud seat knurls with witness knurl grooves in the resonator flange.
NOTE:
Do not tighten the service clamp at this time.
NOTE:
Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.
NOTE:
Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.
NOTE:
Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.
NOTE:
Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.