88 Thunderbird/Cougar 3.8L Engines - Federal

Service Part Number



AFFECTED VEHICLES:
1988 Model Thunderbird/Cougar - 49 States. 3.8L engines





Inspection for Service Part Replacement (Underbody Catalyst)

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.

2. Proceed to Substrate Drilling Inspection.


Substrate Drilling Inspection

- Refer to Attachment IV, for Substrate Integrity Drilling Instructions.

Underbody Catalytic Converter

Removal

1. Raise vehicle.

2. Remove bolts attaching toeboard catalytic converter assembly to underbody catalytic converter.

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 rod into hanger bracket.

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

Toeboard Catalytic Converter

Removal

1. Raise vehicle.

2. Disconnect managed thermactor air tube (MTA) and valve assembly from inlet pipe.

3. Remove nuts attaching converter Y-pipe assembly flanges to exhaust manifolds.

4. Remove toeboard catalytic converter.

Installation

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

2. Position underbody converter to outlet flange of toeboard converter using new gasket and install retaining bolts. Do not tighten bolts.

3. Position converter Y-pipe assembly to exhaust manifold flanges and install nuts. Do not tighten nuts.

4. Align exhaust system.

5. With exhaust system aligned:

a. Tighten toeboard to underbody converler bolts to 27-41 N-m (20-30 Lb.Ft.).

b. Tighten converter Y-pipe assembly-to-exhaust manifold nuts to 22-32 N-m (16-24 Lb.Ft.).

c. Tighten muffler inlet pipe-to-underbody converter outlet flange retaining nuts to 27-41 N-m (20-30 lb.ft.).

6. Connect MTA tube and valve assembly to inlet pipe.

7. Check system for leaks.

8. 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.