Catalytic Converter

Catalytic Converter - 5.4L

Removal

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. NOTICE: When repairing the exhaust system or removing exhaust components, disconnect all Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) at the wiring connectors to prevent damage to the sensors and wiring harnesses.

Disconnect the RH Heated Oxygen Sensor (HO2S) electrical connector.

3. Disconnect the LH and RH Catalyst Monitor Sensor (CMS) electrical connectors.

4. Using a jackstand, support the intermediate pipes.

5. Loosen the 2 Torca(R) couplers.
- Slide the Torca(R) couplers on to the intermediate pipe and disconnect the intermediate pipe from the catalytic converter assembly.

6. Using a jackstand, support the catalytic converter.

7. Remove and discard the 2 RH catalytic converter-to-exhaust manifold nuts.

8. Remove and discard the 2 LH catalytic converter-to-exhaust manifold nuts.

9. Remove the jackstand and the catalytic converter.

Installation

1. NOTICE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.

NOTE: Using a Scotch Brite(R) pad, clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare, at the catalytic converter outlet flare and the muffler inlet pipe. Keep foreign materials out of the catalytic converters.

NOTE: Using a jackstand, support the catalytic converter near the rear outlet while positioning the converter into place. Align the manifold studs into the pipe flange. Make sure not to damage the studs or mating surfaces.

Install the catalytic converter and the new LH and RH catalytic converter-to-exhaust manifold nuts.

- Tighten to 40 Nm (30 lb-ft).

2. NOTE: Make sure that the catalytic converter is inserted into the Torca(R) couplers correctly.

Slide the Torca(R) couplers over catalyst pipes and engage the coupler clip completely over the converter button.

- Tighten to 48 Nm (35 lb-ft).





3. Connect the RH and LH CMS electrical connectors.

4. Connect the RH HO2S electrical connector.