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Catalytic Converter - 1.7L > < Exhaust System

Puma 1998 (06.1997-12.2001)

Exhaust System - Catalytic Converter—1.6L Zetec-SE (Sigma)/1.4L Zetec-SE (Sigma) Puma 1998 (06/1997-12/2001)
Removal and Installation

Removal

  1. Disconnect the battery ground cable.

  1. Remove the exhaust manifold heat shields.
    • Remove 10 bolts.

  1. Disconnect the three way catalytic converter (TWC) from the manifold.
    • Remove and discard the five retaining nuts and any studs which are also removed.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Remove the gear shift linkage stabilizer bolt. For additional information, refer to Section  308-06 Manual Transmission/Transaxle External Controls.

  1. Remove the roll restrictor to transaxle retaining bolt.

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

  1. Disconnect the TWC and flexible pipe assembly from the exhaust system.

  1. Remove the left and right-hand side TWC heat shield bolts (right-hand side shown).
    • Move the heat shield away from the catalytic converter.

  1. Detach the TWC support bracket.

  1. Carefully rock the engine forwards and remove the TWC and flexible pipe assembly.

  1. Remove the support bracket.
    • Remove any remaining studs.

Installation

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

  1. NOTE:
    NOTE:Use five new studs.
    Position the TWC and flexible pipe assembly and install the support bracket.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Use five new nuts.
    Secure the TWC to the exhaust manifold. Tighten the retaining nuts evenly to the initial torque.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Install the roll restrictor to transaxle retaining bolt.

  1. Connect the TWC to the exhaust system.

  1. Install the gear shift linkage stabilizer bolt. For additional information, refer to Section  308-06 Manual Transmission/Transaxle External Controls.

  1. Refit the left and right-hand side TWC heat shield bolts (right-hand side shown).
  1. Remove the flexible pipe support.
  1. Lower the vehicle.

  1. Finally tighten the TWC retaining nuts.

  1. Install the manifold heat shield.
  1. Connect the battery ground cable.

Catalytic Converter - 1.7L > < Exhaust System