Ford DS7Z-5G232-D Exhaust Manifold And Catalyst Assembly

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Using a straightedge and feeler gauge, inspect the exhaust manifold mating surface for warpage. Also check the exhaust manifold surface on the cylinder head. The exhaust manifold or cylinder head must be replaced or resurfaced at an automotive machine shop.

Most models have a catalytic converter that is an integral part of the exhaust manifold.

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.