86-87 Thunderbird/Cougar 3.8L Engines - Federal

Service Part Number



AFFECTED VEHICLES:
1986-87 Model Thunderbird/Cougar (Built after 12,31/85) - 49 States, 3.8L engines





Inspection for Service Part Replacement
1. Locate the slot in the underbody of the catalyst heat shield that shows the catalyst part number. If the part number is E8SC-5E212-CA (Catch Word - ALF), do not replace the catalyst assembly.





^ Prepare an Authorized Modifications Decal (Form-8262-PP) as follows:
Insert your dealer P&A code, "Emissions Recall 91E14" and the date of service. Affix the decal to a clean, flat surface on the fan shroud. Install the clear overlay over the decal.

2. If the catalyst is not the part number, proceed to Substrate Drilling Inspection.


Substrate Drilling inspection

^ Refer to Substrate Integrity Drilling Instructions.


Catalytic Converter

Removal

1. Raise vehicle.

2. Remove bolts atlaching catalytic converter to inlet pipes.

3. Remove nuts attaching muffler inlet pipe to converter outlet flange.

4. Remove converter.

5. Replace any damaged parts.





Installation

1. Install new studs and nuts on converter.

2. Install heat shields. Tighten bolts to 14-20 N-m (11-14 Lb.Ft.).

3. Insert converter hanger rods into hanger brackets.

4. Position converter to inlet pipes using new gaskets and install retaining bolts. Do not tighten bolts.

5. Position muffler inlet flange to converter outlet flange and install retaining nuts. Do not tighten nuts.

6. Align exhaust system.

7. With exhaust system aligned:

a. Tighten converter to Y-pipe bolts to 27-41 N-m (20-30 Lb.Ft.).

b. Tighten muffler inlet pipe to converter outlet flange retaining nuts to 27-41 N-m (20-30 Lb.Ft.).

8. Check system for leaks and lower vehicle.





AUTHORIZED MODIFICATIONS DECAL

The preprinted Authorized Modifications Decal shown 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.