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Catalytic Converter (Zetec and Diesel) - Remove And Install (25 250 0) > < Exhaust System (TC Diesel) - Renew (25 205 0)

Escort.Orion 1991 (08.1990-09.2001)

Exhaust System (Diesel) - Renew (25 205 0)Escort/Orion 1991 (08/1990-09/2001)
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Removal and Installation
Material
Anti‐seize greaseSAM‐1C‐9107A
Remove

CAUTION:

The rubber insulators supporting the catalytic converter are constructed of a special material to cope with the high temperatures in this area. It is important that these remain the correct specification and part number.

NOTE:

The exhaust systems are of two or three piece construction for production, including the catalytic converter, and three piece construction for service replacement exhaust systems. However, for the purposes of this section only, we will be referring to the exhaust system as the portion starting from the flange joint after the catalytic converter and in front of the centre muffler. The catalytic converter will be referred to separately each time by its own name.
It is necessary to cut the production exhaust to enable fitment of the service assembly. Before cutting any part of the exhaust be sure to check the position of the cut is correct in comparison to the service sections to be renewed.
The following illustration shows a complete exhaust system as fitted to Diesel variants.

Muffler Assembly - Centre - Renew (25 233 0)
Muffler - Rear - Renew (25 243 0)
1. Disconnect the exhaust system from the catalytic converter.
   Discard the gasket and nuts.
2. Cut the exhaust pipe as specified to suit the model type and the extent of the section to be renewed.

3. Remove the exhaust system by detaching it from the rubber insulators.

Install
4. Assemble the exhaust system.
   Loosely connect the service exhaust components.
5. Install the exhaust system.
• Examine the rubber insulators for damage/fatigue and renew as necessary.
• Align the exhaust system to the vehicle and attach it into the rubber insulators.

6. Refit the exhaust system to the catalytic converter.
• Use a new gasket and nuts.
• Coat the studs with anti‐seize grease.

7. Check alignment of the system and tighten the nuts.
8. Tighten the pipe clamps.

Catalytic Converter (Zetec and Diesel) - Remove And Install (25 250 0) > < Exhaust System (TC Diesel) - Renew (25 205 0)