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Catalytic Converter: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

    All engines 

  1. If removed, install the catalytic converter hanger bracket and bolts.
    • Do not tighten until the exhaust system has been aligned.
  2. If removed, install the catalytic converter isolator.
  3. If removed, install the exhaust hanger brackets and bolts.
    • Do not tighten until the exhaust system has been aligned.
      • Tighten to 20 Nm (15 lb-ft).
    4. CAUTION: Do not damage the manifold outlet flare, the converter inlet flare or the studs.
    NOTE: Do not tighten the new fasteners until all components are assembled.
    NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare prior to installation.
  4. Install the RH catalytic converter.
    • Do not tighten the new nuts until the exhaust system has been aligned.
  5. Install the RH exhaust shield bolt.
    • Tighten to 15 Nm (11 lb-ft).
    Fig 1: Locating RH Exhaust Shield Bolt
    G03929683Courtesy of FORD MOTOR CO.
    6. CAUTION: Do not damage the manifold outlet flare, the converter inlet flare or the studs.
    NOTE: Do not tighten the fasteners until all components are assembled.
    NOTE: Clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare prior to installation.
  6. Support the RH catalytic converter near the rear outlet, then install the LH catalytic converter.
    • Do not tighten the nuts until the exhaust system has been aligned.
  7. Install the LH exhaust shield bolt.
    • Tighten to 15 Nm (11 lb-ft).
    Fig 2: Identifying LH Exhaust Shield Bolt
    G03964377Courtesy of FORD MOTOR CO.

    8. 4x4 vehicles 

    CAUTION: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with Threadlock and Sealer.
    Fig 3: Positioning Driveshaft And Installing Bolts Using Index Marks As Guide
    G03912443Courtesy of FORD MOTOR CO.
  8. Using the index marks as a guide, position the driveshaft and install the 4 bolts.
    • To install, tighten the bolts to 112 Nm (83 lb-ft) evenly in a cross pattern.

    9. 4.6L and 5.4L engines 

    NOTE: Apply anti-seize lubricant to the threads of the sensors before installation.
    Fig 4: Using Special Tool And Installing HO2S
    G03965027Courtesy of FORD MOTOR CO.
  9. If installing a new converter, use the special tool and install the 2 HO2S.
    • To install, tighten to 40 Nm (30 lb-ft).
  10. Connect the HO2S electrical connector. All engines
    11. NOTE: Apply anti-seize lubricant to the threads of the sensors before installation.
  11. If installing a new converter, use the special tool and install the 2 catalyst monitor sensors.
    • To install, tighten to 40 Nm (30 lb-ft).
  12. Connect the 2 catalyst monitor sensor electrical connectors.
  13. Position a new exhaust clamp onto the Y-pipe and connect the LH catalytic converter to the Y-pipe.
  14. Position the new clamp over the pipe joint. Make sure the back of the slot is covered by the clamp. The clamp is installed no more than 4 mm (0.16 in) from the back of the button on the end of the pipe.
    • Do not tighten the clamp until the exhaust system has been aligned.
    Fig 5: Identifying Coupling Installation Dimensions
    G03924085Courtesy of FORD MOTOR CO.
  15. Install the muffler into the isolators.
  16. Position a new exhaust coupler onto the extension pipe.
  17. Install the extension pipe.
    18. NOTE: Do not tighten the coupler until the exhaust system has been aligned.
    Fig 6: Positioning New Exhaust Coupler Over Extension Pipe-To-Y-Pipe
    G03965022Courtesy of FORD MOTOR CO.
  18. Position the new exhaust coupler over the extension pipe-to-Y-pipe.
  19. Push the muffler forward until the collar on the tailpipe hanger bracket is touching the isolator.
    Fig 7: Pushing Muffler Forward Until Collar On Tailpipe Hanger Bracket Is Touching Isolator
    G03965017Courtesy of FORD MOTOR CO.
  20. Make sure the button on the muffler inlet pipe is fully inserted into the L-notch on the extension pipe.
    Fig 8: Identifying Button On Muffler Inlet Pipe Is Fully Inserted Into L-Notch On Extension Pipe
    G03965018Courtesy of FORD MOTOR CO.
  21. Align the exhaust system. For additional information, refer to EXHAUST SYSTEM ALIGNMENT .
  22. If removed, install the transfer case skid plate.
    • Tighten to 18 Nm (13 lb-ft).
    Fig 9: Installing Transfer Case Skid Plate
    G03965004Courtesy of FORD MOTOR CO.
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