Catalytic Converter - 6.2L: Installation

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Do not tighten any fasteners until all components are aligned.

NOTE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.

NOTE: LH exhaust Y-pipe-to-exhaust manifold flange shown in illustration, RH similar.

Fig 1: Locating Exhaust Y-Pipe-To-Exhaust Manifold Flange Nuts

Courtesy of FORD MOTOR CO.

With the help of an assistant, position the exhaust Y-pipe with dual catalytic converter into the vehicle and loosely install 4 new exhaust Y-pipe-to-exhaust manifold flange nuts.
Loosely install the 2 exhaust Y-pipe with dual catalytic converter-to-resonator bolts.
Make sure the exhaust Y-pipe with dual catalytic converter-to-resonator Torca® clamp is positioned correctly on the resonator.

NOTE: Make sure the exhaust Y-pipe with dual catalytic converter is aligned to provide maximum clearance to adjacent parts.

To seat the LH exhaust Y-pipe-to-exhaust manifold nuts, tighten the nuts in the following sequence.
- Tighten the lower LH exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in).
- Tighten the upper LH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
- Tighten the lower LH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
  
  Fig 2: Locating Exhaust Y-Pipe-To-Exhaust Manifold Flange Nuts
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the exhaust Y-pipe with dual catalytic converter is aligned to provide maximum clearance to adjacent parts.

To seat the RH exhaust Y-pipe-to-exhaust manifold nuts, tighten the nuts in the following sequence.
- Tighten the lower RH exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in).
- Tighten the upper RH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
- Tighten the lower RH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
  
  Fig 3: Locating RH Exhaust Y-Pipe-To-Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
Tighten the 2 exhaust Y-pipe with dual catalytic converter-to-resonator bolts.
- Tighten to 40 Nm (30 lb-ft).
Tighten the 2 Torca® clamp nuts.
- Tighten to 48 Nm (35 lb-ft).
Connect the 2 Heated Oxygen Sensor (HO2S) and the 2 Catalyst Monitor Sensor (CMS) electrical connectors.