Catalytic Converter: Service and Repair

Removal




1. Remove the heat shield.
- Remove the bolts.

2. Remove the heated oxygen sensor (HO2S). Refer to HEATED OXYGEN SENSOR (HO2S) - 2.0L ZETEC.
3. Remove the exhaust gas recirculation (EGR) tube. Refer to EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 2.0L ZETEC.




4. Remove the catalytic converter nuts.
- Discard the nuts.

5. Remove the catalyst monitor sensor. Refer to CATALYST MONITOR SENSOR - 2.0L ZETEC.




6. Remove the bolts.




7. Remove the nuts and bolts.
- Discard the nuts.




8. Loosen the catalytic converter bracket nuts.
9. Remove the catalytic converter.

Installation

1. Position the catalytic converter.
- Install new gaskets.




2. Install new nuts and bolts.




3. Tighten the catalytic converter bracket nuts.
4. Install the catalyst monitor sensor. Refer to CATALYST MONITOR SENSOR - 2.0L ZETEC.




5. Install the new catalytic converter nuts.




6. Install the catalytic converter bracket and bolts.
7. Install the EGR tube. Refer to EXHAUST MANIFOLD TO EXHAUST GAS RECIRCULATION (EGR) VALVE TUBE - 2.0L ZETEC.
8. Install the heated oxygen sensor (HO2S). Refer to HEATED OXYGEN SENSOR (HO2S) - 2.0L ZETEC.




9. Install the bolts and the heat shield.