Catalytic Converter: Service and Repair
Catalytic Converter-2.0L Zetec-ERemoval
1. Raise and support the vehicle.
2. Remove the rear catalyst monitor sensor.
1. Disconnect the catalyst monitor sensor electrical connector.
2. Remove the catalyst monitor sensor.
3. Disconnect the catalytic converter.
4. Remove the lower support bracket.
5. Lower the vehicle.
6. Detach the high-pressure line retaining clips.
7. Remove the exhaust manifold heat shield.
8. Disconnect the front catalyst monitor sensor electrical connector.
9. Remove the front catalyst monitor sensor.
10. Disconnect the EGR tube.
1. Remove the bolt.
2. Remove the tube.
11. Disconnect the catalytic converter.
^ Discard the nuts.
12. Raise and support the vehicle.
13. CAUTION: The catalytic converter must be supported while the support bracket is removed.
Remove the catalytic converter.
^ Remove the front strap.
^ Discard the gaskets.
Installation
1. CAUTION: Failure to follow this instruction may cause damage to the support brackets and the catalytic converter.
Loosen the rear support bracket bolts so that the mating faces are touching, allowing the bracket to slide.
2. Install the catalytic converter.
^ Install a new gasket and nuts.
^ Loosely install the nuts.
3. Loosely connect the catalytic converter to the flexible pipe.
^ Install a new gasket.
4. Install the rear catalyst monitor sensor.
1. Install the rear catalyst monitor sensor.
2. Connect the rear catalyst monitor sensor electrical connector.
5. Lower the vehicle.
6. Tighten the nuts.
7. Connect the EGR tube
1. Install the tube.
2. Install the bolt.
8. Install the catalyst front monitor sensor.
9. Connect the front catalyst monitor sensor electrical connector.
10. Install the exhaust manifold heat shield.
11. Secure the high-pressure line.
12. Raise and support the vehicle.
13. Remove the nut.
14. Install the front bracket.
15. Tighten the bolts
16. Loosely install the lower support bracket.
17. Install the nuts.
^ Use new nuts.
18. Tighten the halts
19. Lower the vehicle.