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Ford Workshop Service and Repair Manuals

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Catalytic Converter - Vehicles Built From: 01-1998 1.6L-1.8L-2.0L > < Dual Converter Y-Pipe

Mondeo 1997 (08.1996-09.2000)

Exhaust System - Catalytic Converter—Vehicles Built Up To: 01/1998 1.6L/1.8L/2.0L Mondeo 1997 (08/1996-09/2000)
Removal and Installation

Materials
Name
Specification
Lubricant
ESE-M99B144-B 
Anti-seize grease
SAM1C9107A 

Removal

  1. Remove the oil level indicator.

  1. Remove the heatshield.
    • Remove the bolts.

  1. Detach the catalytic converter assembly.
    • Remove the nuts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the undershield (if equipped).
    1. Remove the clips.
    1. Remove the bolts.

  1. Disconnect the HEGO sensor.

  1. Remove the HEGO sensor.

  1. Detach the catalytic converter assembly from the exhaust system.
    • Discard the gasket and nuts.

  1. Remove the catalytic converter assembly.
    • Unhook the insulators.

Installation

  1. Prepare the components.
    • Clean the manifold flange to remove carbon deposits.
    • Clean the manifold studs. Install new studs as required.
    • Coat the muffler assembly inlet studs with Anti-seize grease meeting Ford specification.
    • Check the hanger insulators for damage and fatigue. Install new hangers as required.
    • When installing hanger insulators use Lubricant meeting Ford specification.

  1. CAUTION:
    CAUTION:The hanger insulators are constructed of a special material. Use only the correct specification insulators.
    Install the catalytic converter assembly.

  1. Loosely connect the catalytic converter assembly to the exhaust system.
    • Use a new gasket and nuts.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:Never use jointing compound forward of the catalytic converter.
    Connect the catalytic converter assembly to the manifold.

  1. Install the heatshield.
  1. Install the oil level indicator.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Tighten the flange nuts.

  1. Connect and install the HEGO sensor.

  1. Install the undershield (if equipped).
    1. Install the bolts.
    1. Install the clips.
  1. Lower the vehicle.
    • Start the engine and check for leaks or vibration.

Catalytic Converter - Vehicles Built From: 01-1998 1.6L-1.8L-2.0L > < Dual Converter Y-Pipe