Catalytic Converter - 2.3L Manifold, Hybrid: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Install the 7 new catalytic converter studs.
- Tighten to 17 Nm (13 lb-ft).
Position a new catalytic converter manifold gasket on the engine.

CAUTION: Prior to Installation, Inspect the HO2S and the CMS wiring harness for damage.

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.

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

Position the catalytic converter and tighten the 7 exhaust manifold nuts in 2 stages in the sequence shown.
- Stage 1: Tighten to 47 Nm (35 lb-ft).
- Stage 2: Tighten to 47 Nm (35 lb-ft).
  
  Fig 1: Tightening Sequence Of Exhaust Manifold Nuts - 2.3L Manifold, Hybrid
Connect the HO2S and the CMS electrical connectors.
Install the 2 catalytic converter bracket bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the exhaust flexible pipe. For additional information, refer to EXHAUST FLEXIBLE PIPE in this article.