How to Replace Catalytic Converter on Ford Escape and Mercury Mariner?

The procedure is similar for both Ford and Mercury car models:----

The details to replace Exhaust System catalytic converter is as follows:----

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in NEUTRAL, position it on a hoist.
3. Remove and discard the 2 exhaust catalytic converter nuts.
4. Remove and discard the U-bolt clamp assembly from the muffler.
5. Remove and discard the 2 resonator nuts.
6. Remove and discard the catalytic converter exhaust hanger.
7. Remove the exhaust catalytic converter and the muffler from the vehicle as an assembly. Discard the catalytic converter gasket.
8. Separate the converter from the muffler. 
   
   
   
   Fig. Exploded view of the exhaust system-2008 models

To install:

1. Install the converter into the muffler.
2. Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
3. Install the 2 new front and rear gaskets.
4. Install the exhaust catalytic converter and the muffler assembly to the vehicle.
5. Install the exhaust hangers.
6. Tighten the front and rear flange retaining nuts to 35 ft. lbs. (47 Nm).
7. Adjust and tighten the U-bolt clamp to 35 ft. lbs. (47 Nm).
8. Start the vehicle and check for exhaust leaks.

Except Hybrid

Specific to:

Ford Escape 2009

Mercury Mariner 2009

NOTE

If replacement is not required, the production catalytic converter and muffler assembly can be removed and installed as one piece. It is only necessary to cut the production exhaust to enable the service section to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service section being installed.

All Vehicles

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in NEUTRAL, position it on a hoist.

2.5L Engine Vehicles

1. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
2. Remove the CMS.

All Vehicles

1. Remove and discard the two 10 mm exhaust catalytic converter-to-exhaust intermediate pipe/exhaust Y-pipe spring nuts.
2. Remove and discard the two 8-mm resonator-to-muffler spring nuts.
3. Detach the 3 exhaust hangers and remove the catalytic converter and muffler assembly.
4. Remove and discard the gaskets.
5. Cut the exhaust system 5.90 inches (150 mm) as indicated in illustration.
   
   
   

   

   Fig. Cut the exhaust system 5.90 inches (150 mm)

To install:

1. Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
2. Install the service clamp onto the catalytic converter section. Do not tighten the service clamp at this time.
3. Install the catalytic converter section and service clamp onto the muffler section.
   
   
   

   

   Fig. Install the catalytic converter section and service clamp onto the muffler section
4. Inspect the exhaust intermediate pipe/exhaust Y-pipe and resonator flange studs for damage.
5. Attach the catalytic converter and muffler assembly to the 3 exhaust hangers.

2.5L Engine Vehicles

1. Install the Catalyst Monitor Sensor (CMS).

All Vehicles

1. Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.
2. Install a new resonator-to-muffler gasket by hand.
3. Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
   
   
   Stage 1: Tighten to 44 inch lbs. (5 Nm).

   Stage 2: Tighten to 89 inch lbs. (10 Nm).

   Stage 3: Tighten to 150 inch lbs. (17 Nm).
4. Install a new converter-to-exhaust intermediate/exhaust Y-pipe gasket by hand.
5. Install the 2 new 10-mm catalytic converter-to-exhaust intermediate/exhaust Y-pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
   
   
   Stage 1: Tighten to 44 inch lbs. (5 Nm).

   Stage 2: Tighten to 89 inch lbs. (10 Nm).

   Stage 3: Tighten to 150 inch lbs. (17 Nm).
6. Tighten the 4 service clamp nuts to 35 ft. lbs. (47 Nm).

2.5L Engine Vehicles

1. Connect the CMS electrical connector.

Hybrid Models

Specific to:

Ford Escape 2009

Mercury Mariner 2009

NOTE

If replacement is not required, the production catalytic converter and muffler assembly can be removed and installed as one piece. It is only necessary to cut the production exhaust to enable the service section to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service section being installed.

CAUTION

Before proceeding, read and observe all of the High Voltage System Precautions.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
3. Remove the CMS.
4. Remove and discard the two 10 mm exhaust catalytic converter-to-exhaust intermediate pipe/exhaust Y-pipe spring nuts.
5. Remove and discard the two 8-mm resonator-to-muffler spring nuts.
6. Detach the 3 exhaust hangers and remove the catalytic converter and muffler assembly.
7. Remove and discard the gaskets.
8. Cut the exhaust system 5.90 inches (150 mm) as indicated in illustration.
   
   
   

   

   Fig. Cut the exhaust system 5.39 inches (137 mm)

To install:

1. Thoroughly clean the sealing surfaces of the flanges using a finishing pad.
2. Install the service clamp onto the catalytic converter section. Do not tighten the service clamp at this time.
3. Install the catalytic converter section and service clamp onto the muffler section.
   
   
   

   

   Fig. Install the catalytic converter section and service clamp onto the muffler section
4. Inspect the exhaust intermediate pipe/exhaust Y-pipe and resonator flange studs for damage.
5. Attach the catalytic converter and muffler assembly to the 3 exhaust hangers.
6. Install the Catalyst Monitor Sensor (CMS).
7. Thoroughly clean the sealing surfaces of the flanges using a finishing pad. Inspect the cleaned sealing surface for nicks and scratches and replace as necessary.
8. Install a new resonator-to-muffler gasket by hand.
9. Install the 2 new 8-mm resonator-to-muffler spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
   
   
   Stage 1: Tighten to 44 inch lbs. (5 Nm).

   Stage 2: Tighten to 89 inch lbs. (10 Nm).

   Stage 3: Tighten to 150 inch lbs. (17 Nm).
10. Install a new converter-to-exhaust intermediate/exhaust Y-pipe gasket by hand.
11. Install the 2 new 10-mm catalytic converter-to-exhaust intermediate/exhaust Y-pipe spring nuts and alternately tighten RH side to LH side in sequence in 3 stages:
    
    
    Stage 1: Tighten to 44 inch lbs. (5 Nm).

    Stage 2: Tighten to 89 inch lbs. (10 Nm).

    Stage 3: Tighten to 150 inch lbs. (17 Nm).
12. Tighten the 4 service clamp nuts to 35 ft. lbs. (47 Nm).
13. Connect the CMS electrical connector.

These details will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html