Catalytic Converter - 2.0L PZEV: Removal

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Remove and discard the 2 catalytic converter-to-flex pipe flange nuts.

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

Remove and discard the catalytic converter-to-flex pipe gasket.
Remove the 4 catalytic converter-to-engine bracket bolts and the bracket.
Remove and discard the lower 4 catalytic converter nuts and studs.

Fig 1: Locating Catalytic Converter Nuts And Studs
Courtesy of FORD MOTOR CO.

NOTE: It will be necessary to reposition the engine during catalytic converter removal and installation.

Fig 2: Locating Roll Restrictor Bolt

Courtesy of FORD MOTOR CO.

Remove the roll restrictor bolt.
Disconnect the heated oxygen sensor (HO2S) and catalyst monitor electrical connectors.

Fig 3: Identifying Heated Oxygen Sensor (HO2S) And Catalyst Monitor Electrical Connectors
Courtesy of FORD MOTOR CO.
Release the pushpin and disconnect the HO2S electrical connector.

Fig 4: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the 2 pushpin retainers, the evaporative emission (EVAP) canister purge valve and bracket heat shield.

Fig 5: Locating Pushpin Retainers
Courtesy of FORD MOTOR CO.
Disconnect 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.
Remove the EVAP canister purge valve bracket bolts and position the EVAP canister purge valve and bracket aside.

Fig 7: Locating EVAP Canister Purge Valve Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the upper 3 catalytic converter nuts and studs.

Fig 8: Locating Upper Catalytic Converter Nuts And Studs
Courtesy of FORD MOTOR CO.
Disconnect the secondary air hose.

Fig 9: Locating Secondary Air Hose
Courtesy of FORD MOTOR CO.
Remove the engine lifting eyelet bolt and the engine lifting eyelet.

Fig 10: Locating Engine Lifting Eyelet
Courtesy of FORD MOTOR CO.
Remove the valve cover. For additional information, refer to ENGINE - 2.0L AND 2.3L .
- Using shop towels, cover the cylinder head.

NOTE: An assistant will be needed to remove 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 pull the exhaust manifold and catalytic converter assembly upward to remove from the vehicle.
- Discard the gasket.

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

Fig 11: Locating HO2S And Catalyst Monitor

Courtesy of FORD MOTOR CO.

Remove the HO2S and the catalyst monitor.