Walker Ultra EPA 16491 Direct Fit Catalytic Converter User Manual

1. Introduction

This manual provides essential information for the proper installation, operation, and maintenance of your Walker Ultra EPA 16491 Direct Fit Catalytic Converter. Designed for specific Ford and Lincoln models, this converter ensures compliance with EPA emission standards for OBDII vehicles. Please read this manual thoroughly before installation and retain it for future reference.

The Walker Ultra 16491 catalytic converter is engineered for high performance and durability, featuring a direct-fit design for straightforward integration into your vehicle's exhaust system. Its robust stainless steel construction is built to withstand demanding operating conditions, providing reliable emissions control.

2. Safety Information

WARNING: This product can expose you to chemicals including Lead, which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

• Always wear appropriate personal protective equipment (PPE) including safety glasses and gloves during installation.
• Ensure the vehicle is securely supported on jack stands or a lift before working underneath.
• Allow the exhaust system to cool completely before beginning any work to prevent burns.
• Do not modify the catalytic converter. Any alterations may compromise its performance and compliance.
• Consult a qualified automotive technician if you are unsure about any installation steps.

3. Vehicle Compatibility

The Walker Ultra EPA 16491 Catalytic Converter is designed for direct fitment on the following vehicles:

• 2010 Ford Fusion
• 2007-2009 Ford Edge
• 2010 Ford Edge
• 2008-2009 Ford Taurus X
• 2009 Ford Flex
• 2010 Ford Flex
• 2008-2009 Ford Taurus
• 2010-2012 Ford Taurus
• 2007-2010 Lincoln MKZ
• 2007-2010 Lincoln MKX
• 2009-2012 (Additional models may apply, verify fitment)

Important: Before purchasing and installing, verify compatibility by entering your vehicle's year, make, model, engine, and trim information. Check all qualifier notes to ensure correct fitment.

4. Installation Instructions

The Walker Ultra 16491 features a direct-fit design for straightforward bolt-on installation. No specialized fabrication or welding is typically required. However, professional installation is highly recommended due to the complexity and safety considerations involved with exhaust system components.

4.1 Pre-Installation Checks

1. Confirm the new catalytic converter matches the original unit in terms of size, shape, and flange configuration.
2. Inspect the existing exhaust system for any damage, leaks, or corrosion that may affect the new converter's performance or installation.
3. Ensure all necessary gaskets, bolts, and hangers are available and in good condition.

4.2 Removal of Old Converter

1. Safely lift and support the vehicle.
2. Locate the existing catalytic converter.
3. Disconnect any oxygen sensors (O2 sensors) attached to the converter.
4. Unbolt the flanges connecting the converter to the exhaust manifold and the rest of the exhaust system.
5. Carefully remove the old converter, noting the orientation and position of all components.

4.3 Installation of New Converter

1. Position the new Walker Ultra 16491 catalytic converter in place, ensuring correct alignment with the exhaust system.
2. Attach the converter using new gaskets and bolts, tightening them to the manufacturer's specifications.
3. Reconnect any oxygen sensors, ensuring they are properly seated and torqued.
4. Verify that all hangers and brackets are correctly engaged, matching the OE design.
5. Inspect for any potential exhaust leaks before lowering the vehicle.

Figure 1: The Walker Ultra 16491 Catalytic Converter, designed for immediate operation with no break-in period required.

Figure 2: Detail of the OE-style flanges, ensuring a secure and direct fit connection.

Figure 3: Professional installation of a direct-fit exhaust component, highlighting the ease of integration.

5. Operating Principles and Emissions Compliance

The Walker Ultra 16491 Catalytic Converter is a critical component of your vehicle's emission control system. It converts harmful pollutants in the exhaust gases into less toxic substances through chemical reactions.

5.1 Emissions Reduction Technology

This converter utilizes an OE-style high-technology washcoat and an optimal precious metal load to achieve the required reduction in tailpipe emissions. This precision engineering ensures your vehicle meets environmental standards.

5.2 Regulatory Compliance

• EPA Compliant: This converter is compliant for use on OBDII vehicles manufactured in 1996 and newer. It meets federal Environmental Protection Agency standards for emissions.
• CARB Compliant: For states requiring California Air Resources Board (CARB) compliant replacement converters (e.g., California, Colorado, New York), please ensure you purchase the specific CARB-compliant model if required for your region and vehicle year. This specific model (16491) is EPA compliant.

Figure 4: The converter's optimal washcoat technology helps prevent the illumination of the check engine light due to emissions codes.

Figure 5: Walker offers both EPA and CARB compliant converters to meet various state regulations.

6. Maintenance

Catalytic converters are generally maintenance-free components. However, their longevity and efficiency are directly linked to the overall health of your vehicle's engine and exhaust system.

• Regular Engine Maintenance: Ensure your engine is properly tuned, and perform regular oil changes and spark plug replacements as recommended by your vehicle manufacturer. A well-maintained engine prevents unburnt fuel from reaching and damaging the converter.
• Address Engine Malfunctions Promptly: Any issues causing misfires, excessive oil consumption, or rich fuel mixtures can severely damage the catalytic converter. Address check engine light warnings immediately.
• Inspect Exhaust System: Periodically check the entire exhaust system for leaks, corrosion, or damage that could affect the converter's performance.

7. Troubleshooting

If you experience issues after installing your new catalytic converter, consider the following common problems and solutions:

7.1 Check Engine Light (CEL) Illumination

• Cause: Often triggered by an oxygen sensor reading outside normal parameters, or a persistent engine issue.
• Solution:
  1. Ensure O2 sensors are correctly installed and functioning.
  2. Scan the vehicle's onboard diagnostics (OBD-II) system for specific trouble codes.
  3. Address any underlying engine problems (e.g., misfires, fuel system issues) that could be causing the CEL. A new converter will not fix pre-existing engine problems.

Figure 6: The check engine light indicates a potential issue with the vehicle's emissions system or engine.

7.2 Exhaust Leaks

• Cause: Improperly seated gaskets, loose bolts, or damaged flanges.
• Solution: Re-check all connections, ensure gaskets are correctly installed, and tighten bolts to specification.

7.3 Rattling Noise

• Cause: Can indicate a loose heat shield or internal damage to the converter's ceramic substrate.
• Solution: Inspect heat shields for proper attachment. If the noise persists and is internal to the converter, it may require replacement.

8. Product Specifications

9. Warranty and Customer Support

For specific warranty information regarding your Walker Ultra EPA 16491 Catalytic Converter, please refer to the documentation included with your purchase or visit the official Walker website. Warranty terms typically cover manufacturing defects under normal use.

If you have questions about installation, compatibility, or require technical assistance, please contact Walker customer support through their official channels. Ensure you have your product model number (16491) and purchase details available when contacting support.