Ford 8S4Z-5G232-D Exhaust Manifold And Catalyst Assembly

To remove the exhaust manifold on 2008 and later models, follow these steps. Raise the vehicle and support it securely on jackstands. Fabricate and attach a splint along the flexible exhaust section. Remove the exhaust pipe nuts from the end of the catalytic converter/exhaust manifold and remove the catalytic converter-to-engine support brace. Disconnect the wiring from the catalytic converter/exhaust manifold. Remove the upper heat shield. Remove the heat shield from the canister purge valve, then disconnect the wiring from the valve. Detach the fuel supply line from the canister purge valve bracket, then unbolt the bracket and move it out of the way. Remove the catalytic converter/exhaust manifold mounting nuts. Remove the engine lift bracket. Remove the catalytic converter/exhaust manifold and the lower heat shield. Discard the head surface gasket and remove and discard the mounting studs. After cleaning all gasket surfaces and checking all sealing surfaces for flatness, install new mounting studs and tighten them to the torque listed.

Remove the nuts and detach the exhaust manifold and gasket, taking care not to damage vulnerable components. For additional clearance, unscrew the studs from the cylinder head using a female Torx-type socket if necessary.

The catalytic converter generates heat, which promotes the chemical reaction.