A possible cause of the failure of the catalytic converter may be the use of leaded gasoline and non-recommended types of motor oils with high sulfur and phosphorus content.
A sealing gasket made of pressed heat-resistant material reinforced with steel is installed between the flanges of the cylinder head and the exhaust manifold.
For removing the exhaust manifold on 1.6L Duratec Ti-VCT engines perform the following operations.
You will need: 13 and 22 mm wrenches, 10 and 15 mm socket heads, and a flat-blade screwdriver.
1. Remove the mudguard and engine crankcase guard (see Removing and installing mudguard and engine crankcase protection).
2. Remove the front suspension subframe (see Removing and installing the front suspension subframe).
NOTE: It is necessary to remove the subframe because it hinders access to the catalytic converter mounting elements and does not allow the catalytic converter to be removed from the vehicle.
In the process of removing the subframe from the exhaust manifold brackets, two rubber suspension cushions of the exhaust system units are disconnected.
3. Remove the right front wheel drive (see Removing and installing front wheel drives).
NOTE: It is necessary to remove the right front wheel drive because it obstructs access to the exhaust manifold mounting elements.
4. Disconnect the wiring harness connectors of all four oxygen concentration sensors screwed into the catalytic converter…
NOTE: The two sensor pads on the right side of the catalytic converter are shown. The sensor pads on the left side are located symmetrically relative to the longitudinal axis of the vehicle.
5….and remove the sensor harnesses from the holders on the exhaust manifold heat shield.
6. Unscrew the two bolts securing the protective shield to the exhaust manifold…
7….and the engine cylinder block…
8….and then remove the shield.
9. Unscrew the two bolts securing the additional heat shield to the exhaust manifold at its rear…
NOTE: The second bolt securing the heat shield is not visible in the photo; it is located symmetrically relative to the longitudinal axis of the vehicle.
10….two bolts in its front part…
NOTE: The second bolt securing the heat shield is not visible in the photo; it is located symmetrically relative to the longitudinal axis of the vehicle.
11….and remove the heat shield, passing the oxygen concentration sensor wire harnesses through its holes.
12. Unscrew the two nuts securing the flange of the additional muffler to the exhaust manifold.
USEFUL TIP: Before unscrewing the nuts securing the flange of the additional muffler to the exhaust manifold, clean the protruding threaded ends of the studs from dirt and rust with a wire brush, and then treat them with a penetrating lubricant, such as WD-40.
13. Disconnect the main muffler suspension cushions from the brackets (see Replacing the exhaust system suspension cushions), separate the flanges of the additional muffler and the exhaust manifold…
14….and then remove the gasket installed between the flanges.
USEFUL TIP: Replace the sealing gasket between the flanges of the exhaust manifold and the additional muffler with a new one each time the connection is disassembled.
15. Unscrew the four bolts securing the strut to the body base and remove the strut.
16. Unscrew the two nuts securing the exhaust manifold to the cylinder head on the right…
17….and on the left, unscrew one bolt in the center (not visible in the photo)…
18….and then remove the catalytic converter…
19….and the gasket installed on the cylinder head studs.
USEFUL TIP: Replace the exhaust manifold gasket with a new one each time the connection is disassembled.
20. If you are replacing the catalytic converter, and the new catalytic converter does not have oxygen concentration sensors, then unscrew the sensors from the removed catalytic converter and install them on the new unit.
NOTE: Please note that the oxygen sensor wire harnesses are of different lengths. In addition, the color of the pads and harness insulation is different. Install the sensors in the same places on the new catalytic converter as they were on the old one.
21. Install the catalytic converter and all removed parts in the reverse order of removal. Tighten the nuts and bolt securing the catalytic converter in the sequence shown in the photo, to the torque specified in Appendix 1.
For removing the exhaust manifold on 2.0L and 2.3L Duratec-HE engines perform the following operations.
You will need: 13 and 22 mm wrenches, 10 and 15 mm socket heads, and a flat-blade screwdriver.
1. Remove the mudguard and engine crankcase guard (see Removing and installing mudguard and engine crankcase protection).
2. Remove the front suspension subframe (see Removing and installing the front suspension subframe).
NOTE: It is necessary to remove the subframe because it hinders access to the catalytic converter mounting elements and does not allow the catalytic converter to be removed from the vehicle.
In the process of removing the subframe from the exhaust manifold brackets, two rubber suspension cushions of the exhaust system units are disconnected.
3. Remove the right front wheel drive (see Removing and installing front wheel drives).
NOTE: It is necessary to remove the right front wheel drive because it obstructs access to the exhaust manifold mounting elements.
4. Disconnect the wiring harness connectors of the two oxygen concentration sensors screwed into the catalytic converter.
5. Unscrew the two bolts securing the protective shield to the exhaust manifold…
6….and to the engine cylinder block…
7….then remove the shield.
8. Unscrew the two nuts securing the flange of the additional muffler to the exhaust manifold…
USEFUL TIP: Before unscrewing the nuts securing the flange of the additional muffler to the exhaust manifold, clean the protruding threaded ends of the studs from dirt and rust with a wire brush and treat them with a penetrating lubricant, such as WD-40.
9….and disconnect the flanges of the additional muffler and the exhaust manifold.
10. Remove the gasket installed between the flanges.
USEFUL TIP: Replace the sealing gasket between the flanges of the exhaust manifold and the additional muffler with a new one each time the connection is disassembled.
11. Unscrew the four bolts securing the strut to the body base and remove the strut.
12. Unscrew the bolts securing the exhaust manifold protective screen…
13….and remove the protective screen.
14. Unscrew the nuts securing the catalytic converter to the cylinder head, remove the catalytic converter and the gasket installed on the cylinder head studs.
USEFUL TIP: Replace the exhaust manifold gasket with a new one each time the connection is disassembled.
15. Install the catalytic converter and all removed parts in the reverse order of removal. Tighten the catalytic converter mounting nuts evenly crosswise, starting with the middle bolts and moving to the outer ones, to the torque specified in Appendix 1.
[This publication was borrowed from the website: fordbook.ru]