Ford 7E5Z-5E212-AA
Catalytic Converter, Rear

The first step for servicing or repairing the catalytic converter on non-PZEV and 2.3L manifolds requires hoisting the vehicle in NEUTRAL position. Start by removing the generator air inlet duct then detach the heated oxygen sensor (HO2S) along with the catalyst monitor sensor from the vehicle. The wiring harness bracket needs detaching from the valve cover stud before storing it aside. Start by taking out the two nuts which connect the catalytic converter manifold to the exhaust flexible pipe while discarding the parts with both gasket and nuts. First detach the six bolts retaining the heat shield before taking off the shield and pulling out the two brackets and securing bolts of the catalytic converter manifold shield assembly. Liberate the two bolts securing the catalytic converter manifold bracket and detach the seven nuts and catalytic converter manifold while throwing away the nuts and gasket. Clean the manifold after removing the seven manifold studs which also need discarding. Seven new catalytic converter manifold studs should be installed according to sequence then tightened to 17 Nm (13 lb-ft). Install the new catalytic converter manifold gasket by placing it onto the studs but tighten the nuts in a certain order and twice with two torque stages using 55 Nm (41 lb-ft). The installation of the catalytic converter manifold shield bracket requires two bolts that should be tightened to 20 Nm (15 lb-ft) followed by two catalytic converter manifold bracket bolts which need to be tightened to 20 Nm (15 lb-ft). Place the heat shield and secure its six bolts by tightening them to 10 Nm (89 lb-inch). Secure the two catalytic converter manifold-to-exhaust flexible pipe nuts while using new gaskets and tightening them to 40 Nm (30 lb-ft). Attach the wiring harness bracket on the stud while you install both the HO2S and catalyst monitor sensors before reinstating the generator air inlet duct.

Vehicle service for catalytic converters of 2.3L and 3.0L engines begins by mounting it on a hoist at neutral transmission position. The service requires removal of the exhaust flexible pipe-to-catalytic converter nuts as well as the gasket which needs to be discarded. A proper installation requires the user to tighten the nuts to 40 Nm (30 lb-ft). After removing the Torca® clamp you should disconnect the catalytic converter from both the muffler and tailpipe to extract it. The installation process consists of following the opposite steps of removal while using new gasket along with nuts. Complete the procedure by starting the engine to inspect for exhaust leak occurrence.

Tighten them to 40 Nm (30 ft. lbs.).

Install the two catalytic converter manifold shield bracket bolts and the bracket, also tightening to 20 Nm (15 lb-ft).

Remove the three nuts securing the RH catalytic converter, discarding these nuts and the gasket, and tighten the new ones to 40 Nm (30 ft. lbs.) during installation.

The nuts should be tightened to 40 Nm (30 ft. lbs.).

Position a new gasket on the studs.