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Fiesta 2002.25 (11.2001-)

Engine - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) - Exhaust Manifold Fiesta 2002.25 (11/2001-)
In-vehicle Repair

Special Tool(s)

Support Bar, Engine

303-290A (21-140A)

Adapter for 303-290A

303-290-01 (21-140-01)

Adapter for 303-290A

303-290-02 (21-140-02)

Adapter for 303-290A

303-290-03A (21-140-03A)

Adapter for 303-290A

303-290A-14
General Equipment
Exhaust wrap

Removal

  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    Support the exhaust flexible pipe with a support wrap or suitable splint.

  1. Detach the exhaust flexible pipe from the catalytic converter.
    • Discard the gasket and the nuts.
  1. Detach the exhaust system insulators from the exhaust brackets and position it to one side.

  1. Remove the engine support insulator retaining bolt.

  1. Remove the exhaust manifold lower heat shield left-hand retaining bolts.

  1. Remove the exhaust manifold lower heat shield right-hand retaining bolts.
    • Remove the lower heat shield.
  1. Lower the vehicle.

  1. Disconnect the heated oxygen (HO2S) sensor electrical connector.

  1. Disconnect the catalyst monitor sensor electrical connector.

  1. Detach the power steering line support bracket from the cylinder head.

  1. Detach the power steering fluid reservoir from the bracket and position it to one side.

  1. Detach the coolant expansion tank from the bracket and position it to one side.

  1. Install the special tools.

  1. Remove the engine front mount.
    • Discard the nuts.

  1. Using the special tools lower the engine.

  1. Remove the exhaust manifold upper heat shield.

  1. Remove the exhaust manifold retaining bolts and the nuts.
    • Discard the nuts.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the exhaust manifold.
    • Discard the gasket.

Installation

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    Attach the exhaust manifold to the cylinder head.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new exhaust manifold retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the nuts and bolt at this stage.
    Install the exhaust manifold.

  1. Tighten the exhaust manifold upper retaining nuts and bolt in the sequence shown in two stages.
    • Stage 1: 20 Nm.
    • Stage 2: 55 Nm.

  1. Tighten the exhaust manifold lower retaining bolts.

  1. Install the exhaust manifold upper heat shield.

  1. Using the special tools, raise the engine.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.

  1. Remove the special tools.

  1. Attach the coolant expansion tank to the bracket.

  1. Attach the power steering fluid reservoir to the bracket.

  1. Attach the power steering line bracket to the cylinder head.

  1. Connect the catalyst monitor sensor electrical connector.

  1. Connect the heated oxygen (HO2S) sensor electrical connector.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Position the exhaust manifold lower heat shield and install the right-hand retaining bolt.

  1. Install the exhaust manifold lower heat shield left-hand retaining bolts.

  1. Install the engine support insulator retaining bolt.
  1. Attach the exhaust system insulators to the exhaust brackets.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket and new nuts.
    Attach the exhaust flexible pipe to the catalytic converter.
  1. Remove the exhaust flexible pipe support wrap or splint.
  1. Lower the vehicle.
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.25L Duratec-16V (Sigma)/1.4L Duratec-16V (Sigma)/1.6L Duratec-16V (Sigma) (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

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