Catalytic Converter - 2.0L PZEV: Installation

NOTE: If installing a new converter, install the catalyst monitor sensor and the 2 HO2S.

Install the 2 HO2S and the catalyst monitor.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 1: Locating HO2S And Catalyst Monitor
  Courtesy of FORD MOTOR CO.

NOTE: An assistant will be needed to install the exhaust manifold and catalytic converter assembly. Do not let the catalytic converter come in contact with the cylinder head.

Reposition the engine and carefully lower the exhaust manifold and catalytic converter assembly into position.

NOTE: Make sure to apply anti-seize lubricant to the threads of the sensor before installation.

NOTE: Clean the mating surfaces of the exhaust manifold and the catalytic converter mating surfaces.

NOTE: Always install new fasteners and gaskets.

NOTE: Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.

Using a straightedge and feeler gauge, place the straightedge across the catalytic converter flange surface and check for warpage with the feeler gauge. If the reading is greater than 0.76 mm (0.0295 in), install a new catalytic converter, gasket and nuts.
- Install the new gasket and tighten the 7 new nuts and studs to 55 Nm (41 lb-ft) in the sequence shown.
  
  Fig 2: Locating Nuts And Studs
  Courtesy of FORD MOTOR CO.
Install the valve cover. For additional information, refer to ENGINE - 2.0L AND 2.3L .
Install the engine lifting eyelet and the engine lifting eyelet bolt.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 3: Locating Engine Lifting Eyelet
  Courtesy of FORD MOTOR CO.
Connect the secondary air hose.

Fig 4: Locating Secondary Air Hose
Courtesy of FORD MOTOR CO.
Reposition the EVAP canister purge valve and bracket and install the bolts.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 5: Locating EVAP Canister Purge Valve And Bracket Bolt
  Courtesy of FORD MOTOR CO.
Connect the fuel tubes and the EVAP canister purge valve electrical connector.

Fig 6: Locating EVAP Canister Purge Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Install the EVAP canister purge valve heat shield and the 2 pushpin retainers.

Fig 7: Locating EVAP Canister Pushpin Retainers
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector.

Fig 8: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the HO2S and catalyst monitor electrical connectors.

Fig 9: Locating HO2S And Catalyst Monitor Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the roll restrictor bolt.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 10: Identifying Roll Restrictor Bolt
  Courtesy of FORD MOTOR CO.
Install the 4 catalytic converter-to-engine bracket and the bolts.
- Tighten to 47 Nm (35 lb-ft).

NOTE: When installing the catalytic converter, install a new gasket.

Install the new catalytic converter-to-flex pipe gasket.
Install the 2 new catalytic converter-to-flex pipe flange nuts.
- Tighten to 47 Nm (35 lb-ft).