Catalytic Converter - 2.3L PZEV Manifold: Installation

WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

Install the 7 new catalytic converter manifold studs.
- Tighten to 17 Nm (13 lb-ft).
Position a new catalytic converter manifold gasket on the studs.

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

NOTE: Make sure to tighten the nuts in the following sequence in 2 stages.

Position the catalytic converter manifold and tighten the 7 new nuts in the sequence shown, in 2 stages.
- Stage 1: Tighten to 55 Nm (41 lb-ft).
- Stage 2: Tighten to 55 Nm (41 lb-ft).

Fig 1: Exhaust Manifold Nut Torque Sequence

Courtesy of FORD MOTOR CO.

Connect the secondary injection (AIR) hose to the catalytic converter manifold.

Fig 2: Locating Secondary Injection Hose

Courtesy of FORD MOTOR CO.

Tighten the 2 catalytic converter manifold bracket bolts.
- Tighten to 20 Nm (15 lb-ft).
Install the 2 catalytic converter manifold shield bracket bolts and the bracket.
- Tighten to 20 Nm (15 lb-ft).
Position the heat shield and install the 4 heat shield bolts.
- Tighten to 10 Nm (89 lb-in).
Install the 2 catalytic converter manifold-to-exhaust flexible pipe nuts.
- Install a new gasket and nuts.
- Tighten to 40 Nm (30 lb-ft).
Position the wiring harness bracket on the stud.
Connect the HO2S and 2 catalyst monitor sensor electrical connectors.
Install the generator air inlet duct.