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

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To remove the exhaust manifold on 2008 and later models, follow these steps:1. Raise the vehicle and support it securely on jackstands.2. Fabricate and attach a splint along the flexible exhaust section.3. Remove the exhaust pipe nuts from the end of the catalytic converter/exhaust manifold and remove the catalytic converter-to-engine support brace.4. Disconnect the wiring from the catalytic converter/exhaust manifold.5. Remove the upper heat shield.6. Remove the heat shield from the canister purge valve, then disconnect the wiring from the valve.7. Detach the fuel supply line from the canister purge valve bracket, then unbolt the bracket and move it out of the way.8. Remove the catalytic converter/exhaust manifold mounting nuts.9. Remove the engine lift bracket.10. Remove the catalytic converter/exhaust manifold and the lower heat shield.11. Discard the head surface gasket and remove and discard the mounting studs.12.After cleaning all gasket surfaces and checking all sealing surfaces for flatness, install new mounting studs and tighten them to the torque listed.

Disconnect the negative cable from the battery.

On these models, the catalytic converter is part of the exhaust manifold, requiring the unbolting and setting aside of the power steering pump and several other components at the rear of the engine to remove the exhaust manifold/converter from the top.

A sulphurous smell from the exhaust may be noticed, which is more related to the sulfur content of the fuel than the converter itself.