Vehicle: 2002 Ford Taurus V6-3.0L VIN U
Removing & Reinstalling the Dual converter Y-pipe (Haynes Repair Manual)
Note: The exhaust headpipe on these cars is a welded assembly of two catalytic converters and the headpipes for both banks of the engine. The manufacturer calls it the =93dual converter Y-pipe,=94 or simply the Y- pipe. The Y-pipe assembly must be removed for other service work, such as oil pan removal. Refer to Chapter 6 for more information about the catalytic converters.
- Raise the vehicle and support it on jack stands.
- Disconnect the wiring connectors from the four exhaust oxygen (02) sensors. 02 sensors are installed upstream and downstream from both catalytic converters.
- Remove the 02 sensors from the headpipes as follows to get the Y- pipe assembly out of the car: (a) On a Vulcan V6 engine, remove the upstream 02 sensors from each headpipe, just below each exhaust manifold; the downstream sensors can stay in place. (b) On a Duratec V6 engine, remove all four 02 sensors.
- Remove the nuts that secure the front and rear headpipes to the exhaust manifold studs.
- Remove the nuts and bolts from the catalytic converter brackets at the transaxle.
- Remove the nuts and bolts at the flange connection of the Y-pipe assembly to the exhaust system flex tube.
- Remove the Y-pipe assembly from the car. You may want an assistant to help you because the pipe assembly is heavy and awkward.
- Install new gaskets at all exhaust system joints during reinstallation. If the nuts and bolts are corroded, it's a good idea to replace them also.
- Install the rest of the parts in the reverse order of removal. Start the engine, and check for exhaust leaks.
Service and Repair: Dual Converter Y-Pipe (Alldata) Removal
- Disconnect the negative battery cable.
- Remove the bolts and engine roll restrictor.
- Remove the bolt, ground strap, and nut.
- Raise and support the vehicle.
- Remove the splash shield and the air deflector.
- Disconnect the Catalyst Monitor Sensor (CMS) electrical connectors.
- Remove the nuts securing the heat shield and position it out of the way. NOTE: Support the exhaust with mechanic's wire.
- Remove the nuts and disconnect the three-way catalytic converter from the dual converter y-pipe.
- Lower the vehicle.
- Remove the nuts and the bolt.
- Using the special tools, raise the front of the engine.
- Raise the vehicle.
- Remove the bolt. CAUTION: The sharp edges on the converter can cut the CV joint boot. Make sure to protect the halfshaft boot with a suitable covering before removing the converter assembly. Remove the dual Y-pipe converter assembly.
- Remove the gaskets and, if necessary, the Catalyst Monitor Sensors (CMS); discard the gaskets. Installation
- Install the new gaskets and, if removed, install the Catalyst Monitor Sensors (CMS).
- Position the dual converter Y-pipe and loosely start the front nuts and the rear bolt.
- Tighten the bolt.
- Lower the vehicle.
- Tighten the nuts.
- Lower the engine and remove the special tools.
- Tighten the bolt.
- Install the engine roll restrictor and tighten the bolts.
- Position the heat shield. Install the ground strap and tighten the bolt and nut.
- Raise the vehicle.
- Tighten the nuts.
- Connect the three-way converter to the dual converter Y-pipe, and tighten the nuts.
- Connect the CMS electrical connectors.
- Install the splash shield and the air deflector, and tighten the screws.
- Lower the vehicle.
- Connect the battery cable.