Ford Fusion Catalytic Converter (2002-2012)

The Ford Fusion catalytic converter is a key component of the vehicle's exhaust system designed to reduce harmful emissions. It is located between the exhaust manifold and the muffler. It contains a ceramic monolith with a honeycomb structure coated with alumina and precious metals like platinum, rhodium, and palladium to catalyze chemical reactions.

These reactions convert toxic gases such as nitrogen oxides (NOx), hydrocarbons (HC), and carbon monoxide (CO) into less harmful substances like nitrogen, oxygen, water vapor, and carbon dioxide. The catalytic converter operates efficiently at temperatures above 420°C and is usually positioned close to the engine to reach optimal heat quickly.

The catalytic converter in a Ford Fusion is integrated within the anti-pollution exhaust system. Its primary role is to treat exhaust gases before they are expelled into the atmosphere, ensuring the vehicle meets emission standards. Depending on the model and engine, it may be installed directly on the exhaust manifold (close-coupled) or under the vehicle chassis.

This positioning helps the catalytic converter reach the necessary operating temperature quickly and maintain emission control performance.

Symptoms of a bad or failing catalytic converter can include:

• Opaque or dark exhaust smoke
• Unusual metallic noises or vibrations from under the vehicle
• Loss of engine power and sluggish acceleration
• Frequent engine stalls or misfires
• Illumination of the check engine light on the dashboard

These signs suggest that the catalytic converter may be clogged, damaged, or not functioning properly and should be checked promptly.

Diagnosis of catalytic converter problems typically involves several methods:

• Reading OBD-II trouble codes to detect emissions system faults, such as catalyst efficiency codes
• Measuring exhaust backpressure to identify blockages
• Visual inspection for physical damage or signs of melting/fusion inside the converter
• Checking downstream oxygen sensor signals for abnormalities

A qualified mechanic or diagnostic tool can assist in accurately diagnosing the condition of the catalytic converter.

To maintain the catalytic converter and extend its service life, Ford recommends:

• Not letting the engine run for more than 10 seconds without moving the vehicle
• Avoid disconnecting ignition components such as spark plugs while the engine is running
• Using high-quality unleaded petrol or diesel fuel to prevent contaminant deposits
• Performing regular engine oil and spark plug replacements
• Periodic engine check-ups at specialized centers to ensure proper combustion and emission controls

Following these guidelines helps prevent clogging and overheating, which can damage the converter.

Krosfou offers brand-new Ford Fusion catalytic converters manufactured in Europe with a 3-year warranty limited to 100,000 kilometers of use. This warranty covers defects under normal use, provided installation and maintenance guidelines are followed, including replacing sensors and gaskets as required.

• The warranty does not cover damage from negligence, engine mismanagement, or clogging due to short trips preventing proper regeneration.
• Products must be installed by professionals and the Lambda sensor replaced after about 80,000 to 100,000 kilometers.

Returning a product is possible within 30 days if it is unused, in original packaging, and ordered for a vehicle registered in the EU, under Krosfou’s free return policy.

While some experienced DIY enthusiasts may attempt to replace the catalytic converter, it is generally recommended to have this done by a professional mechanic. Proper installation requires:

• Correct fitment of the converter compatible with the specific Ford Fusion model and engine displacement
• Replacing related components like the Lambda sensor and exhaust gaskets
• Use of proper copper connections and ensuring exhaust system tightness
• Verification with an OBD tool post-installation to confirm emissions system function

Incorrect installation can void warranties and cause emission non-compliance or engine issues.

Genuine, high-quality Ford Fusion catalytic converters manufactured by Krosfou are available for order directly from the factory with fast shipping options:

• Standard European delivery: 1 to 6 working days, free for orders above certain amounts
• Express delivery: 24 to 48 hours within Europe and 2 to 4 days internationally via reliable carriers like DHL and UPS
• Out-of-stock products are manufactured within 2 days at the factory in Poland, then shipped express
• Free returns within 30 days for unused products in original packaging if the vehicle registration or VIN was provided

Customers are advised to verify compatibility using their vehicle's year, engine type, and regulatory compliance before ordering.