Attachment III - Technical Instructions

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

AFFECTED VEHICLES:
1986 model Federal Thunderbird Turbo Coupe and Cougar XR7 - 2.3L Turbo Engines having calibration 6-06E-R01 and Automatic Transmissions





Catalytic Converter

Removal

1. Raise vehicle on hoist.

2. Remove converter outlet nuts and studs.

3. Remove nuts and studs at exhaust manifold.

4. Remove converter from vehicle.

Attachment III-A-2
Emissions Recall 93E45

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

Installation





1. Attach heat shields catalyst. Install and tighten attaching hardware as indicated.

2. Position catalyst assembly in vehicle.

3. Align exhaust system and tighten attaching hardware as indicated.

4. Lower vehicle and open hood.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

EMISSIONS SYSTEM MODIFICATION





1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.

2. Install valve and hose assembly as shown.

3. Use tie strap to position assembly.

Labels





PREPRINTED AUTHORIZED MODIFICATIONS LABEL

Authorized Modifications preprinted label is provided in the parts kit.

^ Insert your P&A Code and service date on the authorized modification label. Attach label to the radiator support or the plastic pocket attached to the underside of the hood.

^ Place the clear overlay on the label.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION





SPECIAL INFORMATION LABEL - Test Connector

^ Locate the test connector.

^ Wrap the label around the connector so the label attaches to the wiring and to the label.





SPECIAL INFORMATION LABEL - Revised EGR Vacuum Circuit

^ Attach near the Vehicle Emissions Control Information (VECI) label.

Attachment III-B-1
Emissions Recall 93E45

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

AFFECTED VEHICLES:
1987 model Federal and 1988 model Federal and Canadian Thunderbird Turbo Coupe - 2.3L Turbo Engines having calibrations 7-06E-R10 and R11 and Automatic Transmissions





Catalytic Converter

Removal

1. Raise vehicle on hoist.

2. Remove converter outlet nuts and studs.

3. Remove nuts and studs at exhaust manifold.

4. Remove converter from vehicle.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

Installation





1. Attach heat shields to catalyst. Install and tighten attaching hardware as indicated.

2. Position catalyst assembly in vehicle.

3. Align exhaust system and tighten attaching hardware as indicated.

4. Lower vehicle and open hood.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

EMISSIONS SYSTEM MODIFICATION





1. Refer to Figure 1. Remove the vacuum line from the exhaust gas recirculation (EGR) valve.

2. Install valve and hose assembly as shown.

3. Use tie strap to position assembly.

Labels





PREPRINTED AUTHORIZED MODIFICATIONS LABEL

Authorized Modifications preprinted label is provided in the parts kit.

^ Insert your P&A Code and service date on the authorized modification label. Attach label to the radiator support or the plastic pocket attached to the underside of the hood.

^ Place the clear overlay on the label.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION





SPECIAL INFORMATION LABEL - Test Connector

^ Locate the test connector.

^ Wrap the label around the connector so the label attaches to the wiring and to the label.





SPECIAL INFORMATION LABEL - Revised EGR Vacuum Circuit

^ Attach label close to Vehicle Emissions Control Information (VECI) label.

Attachment III-C-1
Emissions Recall 93E45

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

AFFECTED VEHICLES:
1987 model Federal and 1988 model Federal and Canadian Thunderbird Turbo Coupe - 2.3L Turbo Engines having calibrations 7-05E-R00 and R10 and Manual Transmissions





Catalytic Converter

Removal

1. Raise vehicle on hoist.

2. Remove converter outlet nuts and studs.

3. Remove nuts and studs at exhaust manifold.

4. Remove converter from vehicle.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

Installation





1. Attach heat shields to catalyst. Install and tighten attaching hardware as indicated.

2. Position catalyst assembly in vehicle.

3. Align exhaust system and tighten attaching hardware as indicated.

4. Lower vehicle and open hood.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

EMISSIONS SYSTEM MODIFICATION





1. Refer to Figure 1. Remove the vacuum line from the exhaust gas recirculation (EGR) valve.

2. Install valve and hose assembly as shown.

3. Use tie strap to position assembly.





Labels

PREPRINTED AUTHORIZED MODIFICATIONS LABEL

Authorized Modifications preprinted label is provided in the parts kit.

^ Insert your P&A Code and service date on the authorized modification label. Attach label to the radiator support or the plastic pocket attached to the underside of the hood.

^ Place the clear overlay on the label.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION





SPECIAL INFORMATION LABEL - Test Connector

^ Locate the test connector.

^ Wrap the label around the connector so the label attaches to the wiring and to the label.





SPECIAL INFORMATION LABEL - Revised EGR Vacuum Circuit

^ Attach label close to Vehicle Emissions Control Information (VECI) label.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

AFFECTED VEHICLES:
1986, 87, 88, 89-model Federal and 1988 and 1989 model Canadian Merkur XR4Ti - 2.3L Turbo engines having calibrations 6-05R-R00 and 6-06E-R01 and automatic or manual transmissions.





Catalytic Converter

Removal

1. Raise vehicle on hoist.

2. Remove grounding strap.

3. Remove converter nuts, bolts and springs from front and rear flange joints.

4. Remove catalyst from vehicle.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

Installation

1. Use water to wet the converter pad/spacers.

2. Place the pad/spacers on the converter and install the converter shields.

3. Position catalysts in vehicle.





4. Align exhaust system and tighten attaching hardware as indicated.

5. Lower vehicle and open hood.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION

EMISSIONS SYSTEM MODIFICATION





1. Refer to Figure 1. Remove the vacuum line from exhaust gas recirculation (EGR) valve.

2. Install valve and hose assembly as shown.

3. Use tie strap to position assembly.





Labels

PREPRINTED AUTHORIZED MODIFICATIONS LABEL

Authorized Modifications preprinted label is provided in the parts kit.

^ Insert your P&A Code and service date on the authorized modification label. Attach label to the radiator support or the plastic pocket attached to the underside of the hood.

^ Place the clear overlay on the label.

EXHAUST SYSTEM CATALYST REPLACEMENT AND EMISSIONS CONTROL SYSTEM MODIFICATION





SPECIAL INFORMATION LABEL - Test Connector

^ Locate the test connector.

^ Wrap the label around the connector so the label attaches to the wiring and to the label.





SPECIAL INFORMATION LABEL - Revised EGR Vacuum Circuit

^ Attach label close to the Vehicle Emissions Control Information (VECI) label.