Exhaust system replacement including catalytic converter

Our instruction describes the dismantling of the exhaust system assembly - using the Zetec-E 1.8 / 2.0 L engines as an example - from front to back. If you only replace individual parts, refer only to the relevant repair section - for engines with a displacement of 1.4/1.6 l and turbocharged diesel engines, proceed according to your model. Remember that you should always replace bolts, self-locking nuts, burnt gaskets and brittle rubber mounts with new parts.

Raise the vehicle with a hoist or place it securely on tripods.

Remove the heat shield (four bolts).

Remove the catalytic converter nuts.

Remove the lower holder.

Lower the car.

Dismantle the discharge pipeline (arrows).



Remove the heat shield on the exhaust manifold.

Disconnect the connector (arrow) lambda probe.




Dismantle the lambda probe.

Remove the catalytic converter nuts. Dispose of old nuts.

Raise the vehicle or place it securely on tripods.

Remove the catalytic converter. To do this, dismantle the front fastening tape (arrow) and dispose of gaskets. Important: You must support the catalytic converter while removing the fastening tape.

Installation

Unscrew the bolts on the rear fastening tape (arrow). In order for the holder to move easily with the fastening tape, the adjacent surfaces must be in contact. Important: Otherwise, this can lead to damage to the holders and later to the complete failure of the catalytic converter.




Fit the catalytic converter with new nuts and gaskets - loosely tighten the nuts first.

Connect the flexible pipe loosely to the catalytic converter (use a new gasket).

Lower the car.

Tighten all nuts.

Mount the lambda probe with a new sealing ring.

Connect the lambda probe connector and lay the connecting wire so that it does not vibrate.

Install a heat shield.

Lay and connect the pressure pipe.

Raise the vehicle or place it securely on tripods.

Unscrew the nut (arrow).



Tighten the front fastening tape to 22 Nm.

Tighten the bolts (arrows) force 47 Nm.



Pre-install the lower holder without fastening it. Tighten nuts to 4 Nm and bolts to 22 Nm.


Install a heat shield.

Lower the car and test drive. If necessary, tighten the screw connections.

So the exhaust system will be sealed

You should always use new gaskets and bolts with every exhaust system repair: new gaskets remain flexible and therefore seal better. Leaky systems not only create noise, but also negatively affect power. Be sure to thoroughly clean all sealing surfaces and coat the bolt threads with heat-resistant lubricant paste before mounting.