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Removal And Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in FIRE SUPPRESSION SYSTEM article. Failure to follow the instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
    2. WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this instruction may result in serious personal injury.
  2. If equipped, turn the air suspension switch OFF.
  3. Disconnect the heated oxygen sensor (HO2S) and catalyst monitor sensor electrical connectors.
  4. Remove and discard the 4 catalytic converter-to-exhaust manifold nuts.
    • To install, tighten to 48 Nm (35 lb-ft).
  5. Remove the catalytic converter-to-outlet pipe bolts, the flag nuts and the damper, then remove the catalytic converter.
    • Discard the bolts, the flag nuts and the gasket.
    • To install, tighten to 40 Nm (30 lb-ft).
    6. NOTE: Clean the mating surfaces of the exhaust manifold, the outlet pipe and the catalytic converter.
    NOTE: Always install new exhaust system 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.
    NOTE: To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.

    Alternately tighten the catalytic converter-to-inlet pipe bolts to specification to draw the flanges together evenly.

  6. To install, reverse the removal procedure.
    7. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  7. If equipped with fire suppression system, repower the system.
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