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326 Starting system > < Catalytic Converter (HCS) - Remove And Install (25 250 0)

Escort.Orion 1991 (08.1990-09.2001)

Catalytic Converter (HCS with Downpipe/Catalytic Converter Assembly) - Remove And Install (25 250 0)Escort/Orion 1991 (08/1990-09/2001)
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Removal and Installation
Material
Anti‐seize greaseSAM‐1C‐9107A
Remove

CAUTION:

Disconnect the battery negative lead.

1. Disconnect the heated oxygen sensor multiplug.

2. Remove the manifold heat shield (two bolts).

3. Disconnect the catalytic converter from the manifold (five nuts).
   Discard the nuts and studs.

4. Detach the catalytic converter support bracket (two bolts).
5. Raise the vehicle.

CAUTION:

Over bending of the flexible pipe may cause damage resulting in failure.
6. Support the flexible pipe with a support wrap or suitable splint assembly.

7. Disconnect the catalytic converter (two nuts).
   Discard the gasket and nuts.

NOTE:

If the catalytic converter is to be refitted, care must be taken not to damage the assembly, excessive forces may damage the ceramic substrates.
8. Disconnect the lower support bracket and remove the catalytic converter.
Install

CAUTION:

Over bending of the flexible pipe may cause damage resulting in failure.
9. Support the flexible pipe with a support wrap or suitable splint assembly.

CAUTION:

Never use a jointing compound forward of the catalytic converter.
10. Reposition the catalytic converter and loosely refit the support bracket.
11. Loosely refit the catalytic converter to the exhaust system.
• Use a new gasket and nuts.
• Coat the studs with anti‐seize grease.
12. Lower the vehicle.
13. Loosely refit the upper catalytic converter support bracket.

14. Refit the catalytic converter to the manifold. Tighten the retaining nuts evenly to initial torque.
• Use new nuts and studs as necessary.
• Coat the studs with anti‐seize grease.

15. Fully tighten the catalytic converter retaining nuts.

16. Tighten the upper support bracket nuts.
17. Raise the vehicle.

18. Tighten the catalytic converter flange nuts.
19. Tighten the support bracket.
20. Remove the flexible pipe support.
21. Lower the vehicle.
22. Refit the manifold heat shield.
23. Reconnect the heated oxygen sensor multiplug.
24. Reconnect the battery negative lead.

326 Starting system > < Catalytic Converter (HCS) - Remove And Install (25 250 0)