Catalytic Converter: Service and Repair

Catalytic Converter - 2.0L Zetec

Material

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.

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 bolts and the lower support bracket.
5. Lower the vehicle.

6. Detach the high-pressure line retaining clips.

7. Remove the bolts and the exhaust manifold heat shield.

8. Disconnect the front catalyst monitor sensor electrical connector.

9. Remove the front catalyst monitor sensor.

10. Disconnect the exhaust gas recirculation (EGR) tube.
1. Remove the EGR bolt.
2. Remove the EGR tube.

11. Remove and discard the catalytic converter 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, then remove the front strap. Discard the gaskets.

Installation

1. Loosen the rear support bracket bolts so that the mating faces are touching, allowing the bracket to slide.

2. NOTE: Clean the mating surfaces of the exhaust manifold and the catalytic converter.

Install the catalytic converter with a new gasket and new catalytic converter nuts.
^ Loosely install the nuts at this time.

3. Install a new gasket, then loosely connect the catalytic converter to the flexible pipe.

4. NOTE: Apply anti-seize lubricant to the threads of the sensor before installation.

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. NOTE: To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.

Tighten the catalytic converter nuts.