Service Part Number: Kit A
AFFECTED VEHICLESCERTAIN 1995 AND 1996 CONTOUR AND MYSTIQUE CARS, EQUIPPED WITH 2.5L ENGINE AND BUILT AT THE KANSAS CITY ASSEMBLY PLANT FROM START OF 1995 PRODUCTION THROUGH MARCH 10, 1996, AND CUAUTITLAN ASSEMBLY PLANT FROM START OF PRODUCTION THROUGH MARCH 13, 1996.
SERVICE PART NUMBER:
F6RZ-9K494-CC KIT "A"
USAGE:
1995 MODELS WITH MANUAL TRANSMISSIONS
REMOVAL/INSPECTION
Three-way catalytic converter must be inspected for blockage. If blockage exceeds the inspection limit shown below, the three-way catalytic converter must be replaced.
1. Install memory saver, then disconnect battery negative cable.
2. From engine compartment, perform the following:
^ Disconnect idle air control vacuum hose.
^ Disconnect idle air control electrical connector.
^ Disconnect EGR tube from the EGR valve.
^ Disconnect electrical connectors from both oxygen sensors. One oxygen sensor is located in each catalyst/exhaust manifold.
3. Raise and support vehicle.
4. Remove three-way catalytic converter retaining nuts from muffler inlet and Y-pipe, then remove three-way catalytic from the vehicle and set it aside for re-installation later.
5. Inspect three-way catalytic as follows:
^ Looking through the three-way catalytic converter inlet, inspect substrate for blockage. See Figure 1. If total surface of substrate is 10 percent or more blocked (2 square inches of blockage), the three-way catalytic converter must be replaced.
^ Blockage may not be located in one spot as illustration shows. The blockage may be spread out across the entire substrate and it may be necessary to make an estimate of blockages on the total substrate surface.
6. Remove Y-pipe-to-both catalytic/exhaust manifold retaining nuts.
7. Remove Y-pipe bracket retaining nuts, then remove the Y-pipe from the vehicle.
8. Remove right wheelwell splash shield.
9. Remove right driveshaft bearing support shield retaining nuts, then the shield.
10. Remove right driveshaft bearing support bracket retaining bolts from the engine block. Disengage the bracket from the engine block only.
11. Disconnect alternator electrical wiring.
12. Remove the serpentine drive belt from the alternator pulley.
13. Remove the alternator rear bracket retaining bolt.
14. Remove the alternator mounting bolts, then position the alternator away from the catalyst/exhaust manifold.
15. Remove the oxygen sensor from the rear (right) catalyst/exhaust manifold.
16. Disconnect and discard both Differential Pressure Feedback EGR (DPFE) hoses.
17. Remove the EGR tube from the rear (right) catalyst/exhaust manifold.
NOTE:
The exhaust manifold is attached to the engine with studs and nuts. When removing the nuts, some studs will unscrew from the head.
18. Remove the retaining nuts from the rear (right) catalyst/exhaust manifold.
19. Remove the rear (right) catalyst/exhaust manifold from the vehicle.
20. Remove exhaust manifold gasket.
21. Remove air deflector from under the front bumper.
NOTE:
The exhaust manifold is attached to the engine with studs and nuts. When removing the nuts, some studs will unscrew from the head.
22. Remove the retaining nuts from the front (left) catalyst/exhaust manifold.
23. Remove the front (left) catalyst/exhaust manifold from the vehicle.
24. Remove exhaust manifold gasket.
COMPONENT TRANSFER
1. Transfer the oxygen sensor from the old front (left) catalyst/exhaust manifold to the new catalyst/exhaust manifold.
2. Tighten oxygen sensor to 35-46 Nm (26-34 lb/ft).
INSTALLATION
1. Install any studs that unscrewed from the head.
2. Position new manifold gaskets on both heads.
3. Position new front (left) catalyst/exhaust manifold in the vehicle.
4. Install new front (left) catalyst/exhaust manifold retaining nuts. Tighten the retaining nuts in sequence shown in figure 2, to 18-22 Nm (13-16 lb/ft).
5. Connect the front (left) oxygen sensor electrical connector.
6. Install the air deflector.
7. Position new rear (right) catalyst/exhaust manifold in the vehicle.
8. Install new catalyst/exhaust manifold retaining nuts. Do not final torque retaining nuts at this time.
9. Lower the vehicle.
10. Connect the EGR tube to the EGR valve.Do not final torque retaining nut at this time.
11. Raise and support the vehicle.
12. Connect the EGR tube to the rear (right) catalyst/exhaust manifold.
13. Install new DPFE hoses. See Figure 3.
14. Tighten rear (right) catalyst/exhaust manifold retaining nuts in sequence shown in Figure 2, to 18-22 Nm (13-16 lb/ft).
15. Install oxygen sensor into rear (right) catalyst/exhaust manifold. Tighten sensor to 35-46 Nm (26-34 lb/ft).
16. Route oxygen sensor wiring to oxygen sensor. Do not connect wiring.
17 Position alternator back into position, then install retaining bolts.
18. Install alternator rear bracket. Tighten retaining bolt to 20-30 Nm (15-22 lb/ft).
19. Install serpentine drive belt on alternator pulley.
20. Connect alternator electrical wiring.
21. Position right driveshaft bearing support bracket, then install retaining bolts. Tighten bolts to 21-32 Nm (15-23 lb/ft).
22. Install right driveshaft bearing support shield, then install retaining nuts.
23. Install right wheelwell splash shield.
24. Position Y-pipe on mounting bracket and both catalyst/exhaust manifolds.
25. Install Y-pipe mounting bracket retaining nut. Do not final torque retaining nut at this time.
26. Install Y-pipe-to-both catalyst/exhaust manifold flange retaining nuts. Tighten nuts to 34-46 Nm (26-33 lb/ft).
27. Tighten Y-pipe mounting bracket retaining nut to 30-40 Nm (22-30 lb/ft).
28. Install new gaskets on both ends of three-way catalyst.
29. Position three-way catalytic converter on muffler inlet and Y-pipe.
30. Install three-way catalytic converter to Y-pipe retaining nuts. Tighten nuts to 30-40 Nm (22-30 lb/ft).
31. Install three-way catalytic converter to muffler inlet retaining nuts. Tighten nuts to 34-46 Nm (26-33 lb/ft).
32. Lower vehicle.
33. From engine compartment, perform the following:
^ Connect right (rear) oxygen sensor electrical connector.
^ Tighten EGR tube to EGR valve to 35-45 Nm (26-33 lb/ft).
^ Connector idle air control vacuum hose.
^ Connect idle air control electrical connector.
34. Connect battery negative cable.
35. Remove memory saver.
36. Start vehicle and check for exhaust leaks.
AUTHORIZED MODIFICATION LABEL
^ Prepare and attach the preprinted Authorized Modifications Label provided in the kit of parts. Write you P & A Code and date of repair as shown.
REMOVAL CATALYSTS
Removed catalysts must be returned. An FPS-700 Parts Disposition Tag will be issued to recall the removed catalysts. Return of removed catalysts with the FPS-700 tag attached must be shipped prepaid freight via United Parcel Service (UPS) to the address on the reverse side of the tag.
Refer to the part return shipping procedure in Section 7.0 of the Warranty and Policy manual.
ANY QUESTIONS ON THE HANDLING OF SPECIAL SITUATIONS REGARDING REMOVED CATALYSTS SHOULD BE RESOLVED WITH YOUR SERVICE ZONE MANAGER.