Lincoln Aviator: Exhaust System - 3.0L EcoBoost / Removal and Installation - Catalytic Converter LH

Removal

NOTE: If the catalytic converter is not being replaced, the HO2S and the catalyst monitor sensor do not need to be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.

NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The LH and RH converters can be serviced separately as needed.

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

1. Remove the LH side exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
   

1. 
   On both sides.
   
   • Remove the wheel arch liner to front subframe retainers.
     

1. Disconnect the HO2S electrical connector.
   

1. Disconnect the HO2S electrical connector.
   

1. • Remove the nut.
     
   • Remove the pin-type retainers and the steering shield from the RH subframe.
     

1. Remove the bolt and position the RH underbody shield aside.
   

1. Remove the bolt and position the LH underbody shield aside.
   

1. • Remove the nut.
     
   • Remove the pin-type retainers and the steering shield from the LH subframe.
     

1. Loosen the middle subframe bolts.
   

1. 
   
   • Support the rear of the subframe with adjustable jack stands.
     

   • NOTICE: Only use hand tools when removing rear subframe bolts.

     Loosen the rear subframe bolts.
     
   • Lower the subframe.
     

1. Position an adjustable jack stand under the transmission crossmember.
   

1. Remove and discard the transmission crossmember bolts.
   

1. Lower the jack stand 32 mm(1.25in).
   

1. Remove the LH catalytic converter nuts and discard.
   

1. Remove the bracket studs and nuts. Remove the LH catalytic converter from the vehicle.
   

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

Installation

1. Clean all exhaust connections before reassembly.

1. NOTE: Make sure that new gasket is installed.

   Install the exhaust gasket.
   

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

   Install the catalytic converter and bracket studs and nuts.
   

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

   Install the LH catalytic converter nuts.
   Torque: 35 lb.ft (48 Nm)

1. Tighten the catalyst assembly bracket studs and nuts.
   Torque:
      Studs:   18 lb.ft (25 Nm)
      Nuts:   18 lb.ft (25 Nm)

1. Raise the transmission and crossmember.
   

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

   Install the transmission crossmember bolts.
   Torque: 59 lb.ft (80 Nm)

1. NOTICE: Only use hand tools when installing rear subframe bolts.

   NOTE: Make sure that new bolts are installed.

   Raise the rear of the front subframe and install the bolts.
   Torque: 52 lb.ft (70 Nm)

1. Install the middle subframe bolts.
   Torque: 195 lb.ft (265 Nm)

1. • Install the steering shield and the pin-type retainers at the LH subframe.
     
   • Install the nut.
     

1. Position the LH underbody shield back and install the bolt..
   Torque: 22 lb.in (2.5 Nm)

1. Position the RH underbody shield back and install the bolt.
   Torque: 22 lb.in (2.5 Nm)

1. • Install the steering shield and pin-type retainers at the RH subframe.
     
   • Install the nut.
     

1. Connect the HO2S electrical connector.
   

1. Connect the HO2S electrical connector.
   

1. 
   On both sides.
   
   • Install the wheel arch liner to front subframe retainers.
     

1. Install the LH side exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
   

1. Check the exhaust system for leaks.