Ford Explorer: Exhaust System - 2.3L EcoBoost (201kW/273PS) / Removal and Installation - Catalytic Converter

Removal

  WARNING: When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the engine and wait until they are cool before removing the exhaust system.

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1. Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the HO2S from the catalytic converter.
   Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the muffler inlet pipe assembly.
   Refer to: Muffler Inlet Pipe (309-00 Exhaust System - 2.3L EcoBoost (201kW/273PS)) .
   

1. Remove the catalyst monitor sensor.
   Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   

4x4 vehicles

1. Remove the front Driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).
   

All vehicles

1. Remove and discard the catalytic converter to turbocharger nuts.
   

1. 1. Remove the PIA nuts.
      
   2. Remove the bracket nuts. Remove the bracket and the catalytic converter.
      

1. Remove and discard the gasket.
   

Installation

All vehicles

1. Clean all exhaust connections before reassembly.
   

1. 1. Clean and inspect the gasket surface and the studs. Replace the studs if necessary.
      Torque: 18 lb.ft (25 Nm)

   2. NOTE: Make sure that a new gasket is installed.

      Install a new gasket.
      

1. NOTE: The nuts are only finger tight in this step.

   Install the catalytic converter. Install the mounting bracket and the nuts.
   

1. NOTE: Make sure that new nuts are installed.

   Install the catalytic converter nuts.
   Torque: 35 lb.ft (47.5 Nm)

1. 1. Tighten the nuts.
      Torque: 18 lb.ft (25 Nm)
   2. Tighten the PIA nuts.
      Torque: 18 lb.ft (25 Nm)

4x4 vehicles

1. Install the front Driveshaft.
   Refer to: Front Driveshaft (205-01 Driveshaft, Removal and Installation).
   

All vehicles

1. To install, reverse the removal procedure.
   

1. Check the exhaust system for leaks.