Catalytic Converter - Manifold, Hybrid: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Install the 7 new catalytic converter manifold studs.
- Tighten to 17 Nm (150 lb-in).
Position a new catalytic converter manifold gasket on the studs.

NOTE: 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.

NOTE: 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 following sequence in 2 stages.

Fig 1: Catalytic Converter Manifold Nuts Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown in the illustration, in 2 stages.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).
Tighten the 2 catalytic converter manifold bracket bolts.
- Tighten to 20 Nm (177 lb-in).
Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
- Tighten to 20 Nm (177 lb-in).
Position the catalytic converter manifold shield and install the 6 heat shield bolts.
- Tighten to 10 Nm (89 lb-in).
Install the exhaust flexible pipe to the catalytic converter.
- Install a new gasket and nuts.
- Tighten to 40 Nm (30 lb-ft).
Connect the HO2S and the CMS electrical connectors.