Ford 9E5Z-5G232-A Exhaust Manifold And Catalyst Assembly

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The remainder of installation is the reverse of removal. Run the engine and check for exhaust leaks.

To remove the catalytic converter on V6 engines with the 3.0L engine's rear cylinder head and 3.5L engine's front or rear cylinder head, raise the front of the vehicle and place it securely on jackstands. Remove the engine under cover. Disconnect the upstream and downstream oxygen sensors, remove both oxygen sensors, and remove any heat shield if equipped. Remove the fasteners securing the catalyst's upper mounting flange to the exhaust manifold, as well as the lower mounting flange to the exhaust pipe. Pull the exhaust pipe down to clear the lower end of the catalyst. Remove the catalyst from the exhaust manifold and discard the old gaskets between the flanges. Installation is the reverse of removal, using new flange gaskets.

Using a scraper, remove all old gasket material and carbon deposits from the manifold and cylinder head mating surfaces. Be very careful when scraping on aluminum engine parts.