Catalytic Converter - 2.0L and 2.3L: Installation

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

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

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

Reposition the engine and carefully lower the exhaust manifold and catalytic converter assembly and shield downward. Roll the shield on, toward the LH side of the vehicle. Position the exhaust gasket and exhaust manifold and catalytic converter assembly in the vehicle.

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.
- Tighten the 7 new catalytic converter-to-cylinder head nuts and studs to 55 Nm (41 lb-ft) in the sequence shown.
  
  Fig 2: Locating Catalytic Converter-To-Cylinder Head Nuts
  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 bolt.
- Tighten to 45 Nm (33 lb-ft).
  
  Fig 3: Locating Engine Lifting Eyelet And Bolt
  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 4: Locating EVAP Canister Purge Valve And Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install and connect the upper fuel tube.

Fig 5: Locating Upper Fuel Tube
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 upper heat shield bolts.
- Tighten to 11 Nm (8 lb-ft).
Connect the HO2S electrical connector.

Fig 7: Installing Upper Heat Shield Bolts
Courtesy of FORD MOTOR CO.
Connect the HO2S and catalyst monitor electrical connectors.

Fig 8: 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 9: Locating Roll Restrictor Bolt
  Courtesy of FORD MOTOR CO.
Position the upper heat shield to the lower heat shield and install the 7 screws and the 2 retainer bolts.
- Tighten to 11 Nm (8 lb-ft).
Install the catalytic converter-to-engine bracket and install the 4 bolts.
- Tighten to 47 Nm (35 lb-ft).

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

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