Ford 6W1Z-5E212-B
Catalytic Converter, Passenger Side

All servicing and repair of the catalytic converter must be preceded by disabling fire suppression system operations when present. A hoisted vehicle in NEUTRAL needs electrical power to the air suspension system to be switched off because unexpected air spring behaviors could occur. The technicians must disconnect both heated oxygen sensor (HO2S) and catalyst monitor sensor (CMS) wire connectors. Replace the two catalytic converter-to-exhaust manifold nuts only after installation. Install them at 48 Nm (35 ft. lbs.) torque. Start by taking off the catalytic converter-to-outlet pipe bolts as well as flag nuts and damper until you can pull out the catalytic converter which requires discarding of bolts and flag nuts and gasket. You should put torque at 40 Nm (30 ft. lbs.) when tightening the outlet pipe bolts during installation. The sensor threads of HO2S and CMS require anti-seize lubrication before new catalytic converter installation, and these sensors should be tightened to 41 Nm (30 ft. lbs.). The surfaces which mate need cleaning before applying new gaskets and fasteners. The fasteners need tightening only after you complete the assembly beginning with components positioned at the front of the vehicle. A correct installation of the converter requires alternating torque application between exhaust manifold-to-catalytic converter nuts and catalytic converter-to-inlet pipe bolts according to specified torque values. Repower the fire suppression system as the last step.

Alternately tighten the exhaust manifold-to-catalytic converter nuts and the catalytic converter-to-inlet pipe bolts to specification to ensure even flange alignment.

Clean the mating surfaces of the exhaust manifold, outlet pipe, and catalytic converter, and always use new exhaust system fasteners and gaskets.

Depower the fire suppression system if equipped, ensuring safety during the process.

Disconnect the heated oxygen sensor (HO2S) and catalyst monitor sensor electrical connector.