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Catalytic Converter - 3.0L RH 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.
    CAUTION: If the warpage is greater than 0.76 mm (0.03 inch), replace the RH catalytic converter manifold.
  1. Inspect the RH catalytic converter manifold for warped across the manifold flange area.
    2. NOTE: Apply anti-seize lubricant to the threads of the HO2S and CMS before installation.
  2. If installing a new RH catalytic converter manifold, install the HO2S and CMS using the special tool.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 1: Identifying Special Oxygen Sensor Tool
      G03901976Courtesy of FORD MOTOR CO.
  3. Clean the mating surfaces of the cylinder head and the RH catalytic converter manifold.
  4. Install the 6 new RH catalytic converter manifold studs.
    • Tighten to 11 Nm (8 lb-ft).
  5. Position a new RH catalytic converter manifold gasket on the studs.
    6. CAUTION: Failure to tighten the catalytic converter 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 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 in 2 stages.
  6. Position the RH 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 2: Identifying Catalytic Converter Manifold Nuts Tightening Sequence
      G04682379Courtesy of FORD MOTOR CO.
  7. Install the shield bracket and the 2 RH catalytic converter manifold shield bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
  8. Tighten the 2 RH catalytic converter manifold bracket bolts.
    • Tighten to 20 Nm (15 lb-ft).
  9. Position the RH catalytic converter manifold shield and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  10. Connect the HO2S and CMS electrical connectors.
  11. Install the EGR tube. For additional information, refer to ENGINE EMISSION CONTROL - 3.0L (4V) .
  12. Install the exhaust flexible pipe. For additional information, refer to EXHAUST FLEXIBLE PIPE .
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