Catalytic Converter: Removal

WARNING: This page is about a different car, the 2016 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

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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 below. 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. 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

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