Catalytic Converter - 2.0L and 2.3L: 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 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 assembly gasket.
Remove the 4 catalytic converter-to-engine bracket bolts and remove the bracket.
Remove the 2 retainer bolts and the 7 screws, then separate the lower heat shield from the upper heat shield.

NOTE: It may be necessary to reposition the engine during catalytic converter removal.

Fig 1: Locating Roll Restrictor Bolt

Courtesy of FORD MOTOR CO.

Remove the roll restrictor bolt.
Disconnect the catalyst monitor sensor and heated oxygen sensor (HO2S) electrical connectors.
Remove the upper heat shield bolts.
Disconnect the fuel tubes and the evaporative emission (EVAP) canister purge valve electrical connector.

Fig 2: Locating Fuel Tubes
Courtesy of FORD MOTOR CO.
Disconnect the other end of the upper fuel tube and remove the fuel tube.

Fig 3: Identifying Upper Fuel Tube
Courtesy of FORD MOTOR CO.
Remove the EVAP canister purge valve bracket bolts and position the EVAP canister purge valve and bracket aside.

Fig 4: Locating EVAP Canister Purge Valve Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the 7 catalytic converter-to-cylinder head nuts and studs.
Remove the bolt and the engine lifting eye.

Fig 5: Locating Engine Lifting Eye Bolt
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 and heat shield from the vehicle. Do not let the catalytic converter or the heat shield come in contact with the cylinder head.

Reposition the engine and carefully pull the exhaust manifold and catalytic converter assembly and shield upward. Roll the shield off, toward the RH side of the vehicle. Remove the exhaust manifold and catalytic converter assembly from the vehicle.
- Discard the gasket.

NOTE: If installing a new converter, remove the catalyst monitor sensors.

Fig 6: Locating HO2S And Catalyst Monitor

Courtesy of FORD MOTOR CO.

Remove the 2 HO2S and the catalyst monitor.