Crown Victoria V8-4.6L SOHC VIN W (2005)
7.
Unbolt the joint of the rear catalyst from the H-pipe/Y-pipe.
8.
Remove the catalyst to H-pipe/Y-pipe connection flange gasket and fasteners.
NOTE
IN SOME CASES A VEHICLE MAY BE EQUIPPED WITH AN EXHAUST VIBRATION DAMPENER THAT MUST BE REMOVED AND
THEN REINSTALLED IN STEP 29 OF THE REPAIR PROCESS.
9.
Clean the H-pipe/Y-pipe gasket flange surface.
10.
Using a flash light inspect the inside of the light off catalyst brick by looking into the exhaust pipe. (Figure 2) If the light off catalyst brick is
cracked, melted, or broken. **DO Not Proceed With This TSB.** Replace the entire converter assembly.
11.
If the light off catalyst brick is in good condition install the appropriate catalytic converter kit.
12.
Remove the light off catalyst from the exhaust manifold but do not discard the nuts.
13.
De-burr or remove the weld from the outside and inside of the light off catalyst pipe to allow the service flange to slip over the tube and allow the
flare tool to fit inside the catalyst pipe.
CAUTION
TO AVOID DAMAGE TO THE CATALYST BRICK OR CATALYST PIPE DO NOT PLACE IN A BENCH VISE DURING THE
DE-BURRING PROCESS.
NOTE
ALL WELD MATERIAL SHOULD BE REMOVED FROM THE PIPE.
CAUTION
DO NOT REMOVE ANY ADDITIONAL METAL FROM THE EXHAUST PIPE.
14.
Install the light off catalyst to the exhaust manifold using the old nuts and torque to 30 ft-lbs (40 N.m).
15.
Install service flange on the outlet pipe of the light off catalyst with the chamfer side of the flange pointing towards the rear of the vehicle. Orient
the flange so the center of the flat is lined up with the HEGO boss.
