AutoZone 1999 Buick Park Avenue Ultra 3.8L SFI SC OHV 6cyl | Repair Guides | Engine & Engine Overhaul | Exhaust System | Catalytic Converter | AutoZone.com

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    1999 Buick Park Avenue Ultra 3.8L SFI SC OHV 6cyl

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    Ford Thunderbird/Cougar 1983-1997 Repair Guide

    Catalytic Converter

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    REMOVAL & INSTALLATION



    2.3L Engine
    1. Disconnect the downstream injection air hose at the check valve.
    2.  
    3. Raise and support the front end on jackstands.
    4.  
    5. Remove the nuts attaching the converter inlet pipe to the exhaust manifold.
    6.  
    7. Unfasten the nuts attaching the converter outlet flange to the muffler.
    8.  
    9. Remove the upper and lower heat shields.
    10.  
    11. Remove the converter from the vehicle.
    12.  

    To install:
    1. Installation is the reverse of removal.
    2.  
    3. Always use new clamps. Always replace the pipe ends-to-manifold packings.
    4.  
    5. Always install all parts loosely and align the system, making sure that all clearances between the system parts and surrounding components are adequate. Torque the flange nuts to 30 ft. lbs. (41 Nm) and the manifold nuts to 35 ft. lbs. (47 Nm).
    6.  

    1983 3.8L And 5.0L Engines
    1. Raise and support the car on jackstands.
    2.  
    3. If the converters are the air-injected, dual type, disconnect the air injection tube from the cover.
    4.  
    5. Unbolt the Y-pipe flanges from the converter flanges.
    6.  
    7. Unbolt the converter flange at the manifolds.
    8.  
    9. Slide the inlet pipe rearward until the converters can be removed. Separate the flanges and remove the converters.
    10.  

    To install:
    1. Installation is the reverse of removal.
    2.  
    3. Always use new clamps. Always replace the pipe ends-to-manifold packings.
    4.  
    5. Always install all parts loosely and align the system, making sure that all clearances between the system parts and surrounding components are adequate.
    6.  
    7. Tighten the flange nuts to 30 ft. lbs. (41 Nm) and the manifold nuts to 35 ft. lbs. (47 Nm).
    8.  

    1984-88 3.8L And 1986-87 5.0L Engines
    1. Raise and support the front end on jackstands.
    2.  
    3. Remove the bolts attaching the Y-pipe to the converter inlet flange.
    4.  
    5. Remove the nuts attaching the muffler inlet pipe to the converter outlet flange.
    6.  
    7. Separate the catalytic converter inlet and outlet flange connections.
    8.  
    9. Remove the converter.
    10.  
    11. Installation is the reverse of removal. Always use new clamps. Always replace the pipe ends-to-manifold packings. Always install all parts loosely and align the system, making sure that all clearances between the system parts and surrounding components are adequate. Torque the flange nuts to 30 ft. lbs.; the manifold nuts to 35 ft. lbs.
    12.  

    1984-85 5.0L Engines
    1. Raise and support the car on jackstands.
    2.  
    3. Disconnect the air injection tube from the cover.
    4.  
    5. Unbolt the Y-pipe flanges from the converter flanges.
    6.  
    7. Unbolt the converter flange at the muffler.
    8.  
    9. Slide the inlet pipe rearward until the converters can be removed. Separate the flanges and remove the converters.
    10.  

    To install:
    1. Installation is the reverse of removal.
    2.  
    3. Always use new clamps. Always replace the pipe ends-to-manifold packings.
    4.  
    5. Always install all parts loosely and align the system, making sure that all clearances between the system parts and surrounding components are adequate.
    6.  
    7. Torque the flange nuts to 30 ft. lbs. (41 Nm). and the manifold nuts to 35 ft. lbs. (47 Nm).
    8.  

    1989-96 Vehicles 3.8L, 4.6L And 5.0L Engines
    1. Raise and safely support the car on jackstands.
    2.  
    3. If equipped, detach the heated oxygen sensors at the wiring harness connectors.
    4.  
    5. Remove two nuts retaining the muffler assembly inlet flange to the resonator outlet flange. Disengage muffler inlet flange from resonator outlet flange studs.
    6.  
    7. Remove three screws retaining the left converter shield.
    8.  
    9. Unfasten the four nuts retaining converter pipe flanges to the exhaust manifolds.
    10.  
    11. Slide the converter and resonator assembly rearward to disengage the hanger rods from the hanger insulators. Remove the converter and insulator assembly.
    12.  
    13. On 5.0L engines, remove resonator from converter assembly by loosening U-bolt clamp and pulling resonator from converter.
    14.  
    15. Replace any damaged parts.
    16.  

    To install:
    1. On 5.0L slide resonator over converter so the converter is bottomed into resonator. Position U-bolt and tighten to 25-35 ft. lbs. (34-47 Nm).
    2.  
    3. Engage hanger rods of converter and resonator assembly with transmission mount hanger insulators. Slide converter and resonator assembly forward.
    4.  
    5. Position the converter inlet pipe flanges to the exhaust manifold and install new retaining nuts. Do not tighten the nuts at this time.
    6.  
    7. Align the converter and resonator assembly to conform to all clearance specifications. Tighten all manifold nuts to 17-24 ft. lbs. (22-33 Nm).
    8.  
    9. Position the left side converter shield and tighten the retaining bolts to 54-115 inch lbs. (6-13 Nm).
    10.  
    11. With the muffler assembly supporter by hangers, install the muffler inlet flange over the resonator outlet flange studs. Install but do not tighten the retaining nuts.
    12.  
    13. Align the muffler and conform to clearance specifications. Tighten the flange nuts to 20-30 ft. lbs. (27-40 Nm).
    14.  
    15. Attach the heated oxygen sensors to the wiring harness connectors.
    16.  
    17. Carefully lower the vehicle, then start the engine and check for exhaust leaks.
    18.  

     
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