Ford FS7Z-5G232-A Exhaust Manifold And Catalyst Assembly

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Check the manifold for warpage and have it resurfaced if necessary.

To remove the catalytic converter on 2010 and later models with a 2SL four-cylinder engine and Non-Partial Zero Emissions (PZEV) vehicles, raise the vehicle and place it securely on jackstands. Disconnect the downstream oxygen sensor's electrical connector, unscrew and remove the downstream oxygen sensor from the catalyst. Remove the nuts and bolts securing the flange at the front end of the catalyst to the exhaust down pipe. Loosen the fasteners on the clamp securing the rear end of the catalyst to the exhaust system. Remove the catalytic converter and old gasket between the exhaust down pipe and the catalyst mounting flange. Installation is the reverse of removal, using a new gasket and, if necessary, new fasteners.

Using a scraper, remove all traces of gasket material from the mating surfaces and inspect them for wear and cracks. Caution: When removing gasket material from any surface, especially aluminum, be very careful not to scratch or gouge the gasket surface. Any damage to the surface may cause an exhaust leak. Gasket removal solvents are available from auto parts stores and may prove helpful.