Fusion FWD V6-3.0L (2009)
Catalytic Converter: Service and Repair
Catalytic Converter - LH Manifold
Catalytic Converter - 3.0L LH Manifold
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove and discard the oil filter.
3. Remove the oil level indicator and tube.
4. Remove the Heated Oxygen Sensor (HO2S) and the catalyst monitor sensor.
5. Remove the 2 LH catalytic converter-to-exhaust flexible pipe nuts.
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Discard the gasket and the 2 nuts.
6. Remove the 4 bolts and the LH catalytic converter manifold shield.
7. Remove the 2 LH catalytic converter manifold shield bracket bolts and the shield bracket.
8. Loosen the 2 LH catalytic converter manifold bracket bolts.
9. Remove the 6 nuts and the LH catalytic converter manifold.
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Discard the 6 LH catalytic converter manifold nuts and the gasket.
10. Remove and discard the 6 LH catalytic converter manifold studs.
11. Clean and inspect the catalytic converter manifold.
Installation
1. Install the 6 new LH catalytic converter manifold studs.
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Tighten to 11 Nm (97 lb-in).
2. Position a new LH catalytic converter manifold gasket on the studs.
3. Position the LH catalytic converter manifold and finger tighten the 6 new nuts.
4. Install a new gasket and finger tighten 2 new nuts at the LH catalytic converter-to-exhaust flexible pipe.
5. NOTICE: Failure to tighten the catalytic converter manifold nuts to specification before installing the converter bracket bolts will cause
the converter to develop an exhaust leak.
NOTICE: Failure to tighten the catalytic converter manifold nuts to specification a second time will cause the converter to develop an
exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence shown in 2 stages.
Position the LH catalytic converter manifold and tighten the 6 new nuts in the sequence shown, in 2 stages.
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Stage 1: Tighten to 20 Nm (177 lb-in).
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Stage 2: Tighten to 20 Nm (177 lb-in).
6. Install the shield bracket and the 2 LH catalytic converter manifold shield bracket bolts.
