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

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Undo the bolts and remove the exhaust manifold lower retaining bracket.

Disconnect the catalytic converter intake pipe from the exhaust manifold and remove the nuts and studs that secure the EGR tube to the exhaust manifold.

To remove the intake manifold on models through 2004, follow these steps:1. Depressurize the fuel system and disconnect the negative battery cable.2. Remove the air cleaner and inlet duct, and disconnect the accelerator cable.3. For 2.3L and 2005 and later 2.0L models, remove the engine cooling fan and shroud.4. Disconnect the brake booster vacuum hose from the base of the manifold and remove the engine oil dipstick and its tube.5. Disconnect the injection harness wiring plug and camshaft position sensor at the rear of the cylinder head.6. Disconnect all electrical connectors from the throttle body.7. For models through 2004, disconnect the fuel supply and return lines from the fuel rail, protecting the alternator from fuel spillage.8. If equipped, disconnect the intake manifold runner control (IMRC) cable.9. Remove the manifold support bracket (SPI engines) and manifold retaining bolts.10. Withdraw the manifold from the engine, keeping it as level as possible, and recover the four gaskets (new ones must be used on installation).

Rough treatment or driving through deep water can damage the ceramic structure of a catalytic converter.