Catalyst and Y-Pipe Assembly Replacement Kit "E" Instructions

AFFECTED VEHICLES: 1984-85 Model Thunderbird/Cougar - 49 states 5.0L engines with calibration code 4-22F-R00/R10.

Catalytic Converter

Removal

1. Raise the vehicle.
2. Remove the air injection tube and check valve.
3. Remove bolts attaching catalytic converter to inlet pipes.
4. Remove nuts attaching muffler inlet pipe to converter outlet flange.
5. Remove converter.
6. Replace any damaged parts.





Installation

1. Position spacers above and below converter.
2. Install heat shields.
3. Insert converter hanger rods into the hanger brackets.
4. Position converter to inlet pipes using new gaskets and install attaching bolts. Do not tighten bolts.
5. Position muffler inlet flange to converter outlet flange and install attaching nuts. Do not tighten nuts.
6. Align exhaust system, refer to illustration.
7. With exhaust system aligned:
a. Tighten converter to inlet pipe bolts to 20-30 N-m (14-22 Lb.Ft.).
b. Tighten muffler inlet pipe to converter outlet flange attaching nuts to 27.1-40.6 N-m (20-29 Lb.Ft.). Refer to illustration.
c. Install the air tube and check valve.
8. Check system for leaks and lower vehicle.





AUTHORIZED MODIFICATIONS DECAL

The preprinted Authorized Modifications Decal shown below is provided in the parts kit.

^ Insert your P & A Code and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud.

^ Place the clear overlay on the decal.