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Catalytic Converter - 3.0L LH Manifold: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the 6 new LH catalytic converter manifold studs.
    • Tighten to 11 Nm (8 lb-ft).
  2. Position a new LH catalytic converter manifold gasket on the studs.
  3. Position the LH catalytic converter manifold and finger tighten the 6 new nuts.
  4. Install a new gasket and the 2 nuts at the LH catalytic converter-to-exhaust flexible pipe.
    • Tighten to 40 Nm (30 lb-ft).
    5. CAUTION: Failure to tighten the catalytic converter manifold 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 manifold 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 shown in 2 stages.
  5. Position the LH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2 stages.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 20 Nm (15 lb-ft).
      Fig 1: Identifying Catalytic Converter Manifold Nuts Tightening Sequence
      G04682374Courtesy of FORD MOTOR CO.
  6. Install the shield bracket and the 2 LH catalytic converter manifold shield bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
  7. Tighten the 2 LH catalytic converter manifold bracket bolts.
    • To install, tighten to 20 Nm (15 lb-ft).
  8. Position the LH catalytic converter manifold shield and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
  9. Install the 2 LH catalytic converter-to-exhaust flexible pipe nuts in 3 stages:
    • Stage 1: Tighten the passenger side nut to 5 Nm (44 lb-in).
    • Stage 2: Tighten the driver side nut to 40 Nm (30 lb-ft).
    • Stage 3: Tighten the passenger side nut to 40 Nm (30 lb-ft).
  10. Install the heated oxygen sensor (HO2S) and the catalyst monitor sensor (CMS). For additional information refer to ELECTRONIC ENGINE CONTROLS - 3.0L (4V) .
  11. Install the oil level indicator and tube. For additional information, refer to ENGINE - 3.0L (4V) .
  12. Install a new oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
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