Catalytic Converter - 3.0L RH Manifold: Installation

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Install the 6 new RH catalytic converter manifold studs.
- Tighten to 11 Nm (8 lb-ft).
Position a new exhaust manifold gasket.

CAUTION: Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.

CAUTION: Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.

CAUTION: Prior to Installation, inspect the Heated Oxygen Sensor (HO2S) wiring harness for damage.

NOTE: Make sure to tighten the nuts in the sequence in 2 stages.

Position the RH catalytic converter and tighten the 6 exhaust manifold nuts in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
  
  Fig 1: Identifying Tightening Sequence Of Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Connect the EGR tube nut to the RH catalytic converter.
- Tighten to 40 Nm (30 lb-ft).
Connect the HO2S electrical connector.
Install the exhaust Y-pipe. For additional information, refer to Exhaust Y-Pipe - 3.0L this article.