Catalytic Converter: Removal

WARNING: This page is about a different car, the 2015 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Before beginning any service procedure in this service information, refer to Safety Warnings in GENERAL INFORMATION . Failure to follow this instruction may result in serious personal injury.

1.

Refer to: Health and Safety Precautions .

2.

With the vehicle in NEUTRAL, position it on a hoist. REFER to: Jacking and Lifting - Overview .

3.

Remove the engine appearance cover.

GFD62017

Courtesy of FORD MOTOR COMPANY

4.

Detach the wiring harness retainers and disconnect the HO2S and catalyst monitor sensor electrical connectors.

GFD63139

Courtesy of FORD MOTOR COMPANY

5.

Remove the bolts and the heat shield.
Torque

: 89 lb.in (10 Nm)

GFD63140

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6.

NOTE: Failure to tighten the catalytic converter manifold nuts to specification a second time may cause the converter to develop an exhaust leak.

NOTE: Discard the nuts.

NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.

During installation, install 5 new catalytic converter manifold-to-cylinder head nuts and tighten in 2 stages in the sequence shown in illustration. Remove the exhaust manifold nuts.

Torque

: 41 lb.ft (55 Nm)

7.

Torque
: 41 lb.ft (55 Nm)

Fig 1: Catalytic Converter Manifold-To-Cylinder Head Nuts Tightening Sequence

GFD63141

Courtesy of FORD MOTOR COMPANY

8.

Remove the front subframe. REFER to: Front Subframe .

9.

NOTE: Failure to tighten the catalytic converter manifold-to-muffler and tailpipe nuts to specification in this sequence may cause the catalytic converter manifold-to-muffler and tailpipe flange to develop an exhaust leak.

NOTE: Always install new fasteners and gaskets as indicated. Clean flange faces prior to new gasket installation to make sure of proper sealing.
- During installation, install 2 new catalytic converter manifold-to-muffler and tailpipe nuts and tighten in 2 stages in the sequence shown in illustration. Remove and discard the nuts and gasket.
  Torque
  
  : 35 lb.ft (48 Nm)
- Position back the exhaust system.

GFD60646

Courtesy of FORD MOTOR COMPANY

10.

Remove the bolts for the exhaust manifold.
Torque

: 18 lb.ft (25 Nm)

GFD63142

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11.

Remove and discard the exhaust manifold gasket and the exhaust manifold studs.
Torque

: 150 lb.in (17 Nm)

GFD63143

Courtesy of FORD MOTOR COMPANY