Ford HS7Z-5G232-A Exhaust Manifold And Catalyst Assembly

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All 2006 through 2009 models have catalytic converters that are integral components of the exhaust manifolds and cannot be serviced separately. For 2010 and later models with a 2SL four cylinder engine and Non-Partial Zero Emissions (PZEV) vehicles, the catalyst is located under the vehicle. To remove the catalytic converter, raise the vehicle and place it securely on jackstands. Locate the downstream oxygen sensor on the upper central part of the catalyst, trace the sensor to its electrical connector and disconnect it. Unscrew and remove the downstream oxygen sensor from the catalyst. Remove the nuts and bolts that secure the flange at the front end of the catalyst to the exhaust down pipe. Loosen the fasteners on the clamp that secures the rear end of the catalyst to the exhaust system. Remove the catalytic converter and discard the old gasket between the exhaust down pipe and the catalyst mounting flange. Installation is the reverse of removal, using a new gasket and, if necessary, new fasteners. For Partial Zero Emissions (PZEV) vehicles with a 2.0L engine, the catalytic converter is an integral component of the exhaust manifold and cannot be serviced separately. For V6 engines, the front cylinder head (3.0L engine) has the catalyst as an integral component of the exhaust manifold. For the rear cylinder head (3.0L engine) and front or rear cylinder head (3.5L engine), raise the front of the vehicle and place it securely on jackstands. Remove the engine under cover. Locate the upstream and downstream oxygen sensors, trace their electrical leads to their respective connectors and disconnect them. Remove both oxygen sensors. If the catalyst or exhaust manifold is equipped with a heat shield, remove the heat shield bolts and remove the heat shield from the exhaust manifold. Remove the fasteners that secure the heat shield mounting bracket and remove the bracket. Remove the fasteners that secure the catalyst's upper mounting flange to the exhaust manifold. Remove the fasteners that secure the lower mounting flange to the exhaust pipe. Pull the exhaust pipe down far enough to clear the lower end of the catalyst. Remove the catalyst from the exhaust manifold and remove and discard the old gaskets between the exhaust manifold flange and the upper catalyst flange and, if equipped, between the lower catalyst flange and the exhaust pipe flange. Installation is the reverse of removal, using new flange gaskets.