Ford Fiesta: Exhaust System - 1.6L EcoBoost (132kW/180PS) – Sigma / Catalytic Converter. Removal and Installation

Special Tool(s) / General Equipment

Removal

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

NOTE: Removal steps in this procedure may contain installation details.

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the battery tray.
   Refer to: Battery Tray - 1.6L EcoBoost (132kW/180PS) – Sigma (414-01 Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the engine appearance cover.
   

1. Detach the wiring harness retainer, then disconnect the HO2S and catalyst monitor sensor electrical connectors.
   

1. NOTICE: Gearshift cables must not be kinked or bent.

   • Disconnect the selector lever cable. Detach the selector lever cables from the selector lever cable brackets.
     
   • Disconnect the electrical connector.
     

1. Remove the bolts and the bracket.
   Torque: 18 lb.ft (25 Nm)

1. Remove the HO2S .
   Refer to: Heated Oxygen Sensor (HO2S) (303-14B Electronic Engine Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Remove the CMS (catalyst monitor sensor).
   Refer to: Catalyst Monitor Sensor (303-14B Electronic Engine Controls - 1.6L EcoBoost (132kW/180PS) – Sigma, Removal and Installation).
   

1. Remove the bolts and the heat shield.
   Torque: 89 lb.in (10 Nm)

1. Remove and discard the catalytic converter bolt.
   

1. NOTICE: Do not excessively bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

   Support the exhaust flexible pipe with a support wrap or suitable splint.
   Use the General Equipment: Cable Ties

1. Remove the nuts and the catalytic converter mounting bracket.
   Torque: 18 lb.ft (25 Nm)

1. Detach the exhaust system isolator and position the exhaust system aside.
   

1. • Remove and discard the nuts.
     Torque: 35 lb.ft (48 Nm)
   • Remove and discard the gasket.
     
   • Position the exhaust system aside.
     

1. Remove and discard the catalytic convertor bolts.
   

1. 1. Position the catalytic converter upward.
      
   2. Remove the catalytic convertor.
      

1. Remove and discard the catalytic converter to TC gasket.
   

Installation

1. To install, reverse the removal procedure.
   

1. Install a new gasket and loosely install the 2 bolts.
   

1. NOTICE: Failure to tighten the catalytic converter manifold fasteners in this sequence will cause the converter to develop an exhaust leak.

   NOTE: Tighten the catalytic converter bolts in this sequence.

   1. Position the catalytic converter on the 2 bolts and install the upper bolt.
      Torque: 18 lb.ft (25 Nm)
   2. Tighten the RH catalytic converter bolt.
      Torque: 18 lb.ft (25 Nm)
   3. Tighten the LH catalytic converter bolt.
      Torque: 18 lb.ft (25 Nm)