ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel > < Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V
Exhaust System - Catalytic Converter—1.8L Duratorq-TDCi (Lynx) Diesel Focus 2004.75 (07/2004-)
Removal and Installation

Name
Specification
Grease
SA-M1C9107-A 
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. Remove the engine undershield.

  1. Remove the floor panel brace.

  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 splint.

5. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
2
-
Exhaust hanger insulators
See Removal Detail
3
-
Catalytic converter to turbocharger retaining nuts
See Removal Detail
4
-
Catalytic converter to catalytic converter support bracket retaining nuts
See Removal Detail
5
-
Catalytic converter

6. Install the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
2
-
Catalytic converter to turbocharger retaining nuts
See Installation Detail
3
-
Exhaust hanger insulators
See Installation Detail
4
-
Catalytic converter to muffler and tailpipe assembly retaining nuts
See Installation Detail

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

  1. Install the floor panel brace.

  1. Install the engine undershield.
  1. Lower the vehicle.

Removal Details

Item 1 : Catalytic converter to muffler and tailpipe assembly retaining nuts

  1. CAUTION:
    CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure.
    NOTE:
    NOTE:Use a pry bar to prevent the exhaust flexible pipe from twisting when removing the catalytic converter to muffler and tailpipe assembly retaining nuts.
    Remove the catalytic converter to muffler and tailpipe assembly retaining nuts.
    • Discard the catalytic converter to muffler and tailpipe assembly gasket and retaining nuts.

Item 2 : Exhaust hanger insulators

CAUTION:
CAUTION:Take care when removing the exhaust hanger insulators to prevent damage.

Item 3 : Catalytic converter to turbocharger retaining nuts

  1. Remove and discard the catalytic converter to turbocharger retaining nuts.

Item 4 : Catalytic converter to catalytic converter support bracket retaining nuts

  1. Remove the catalytic converter to catalytic converter support bracket retaining nuts.

Installation Details

Item 1 : Catalytic converter

  1. CAUTION:
    CAUTION:The catalytic converter to catalytic converter support bracket retaining nuts must be loosely installed to allow the catalytic converter to align with the turbocharger.
    NOTE:
    NOTE:Make sure that the catalytic converter to catalytic converter support bracket studs align with the holes in the catalytic converter support bracket.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter to catalytic converter support bracket retaining nuts at this stage.
    Install the catalytic converter to catalytic converter support bracket retaining nuts.

Item 2 : Catalytic converter to turbocharger retaining nuts

  1. CAUTION:
    CAUTION:Never use jointing compound forward of the catalytic converter.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter to turbocharger retaining nuts at this stage.
    Install the catalytic converter to turbocharger retaining nuts.

  1. Tighten the catalytic converter to turbocharger retaining nuts in the sequence shown.

  1. Tighten the catalytic converter to catalytic converter support bracket retaining nuts.

Item 3 : Exhaust hanger insulators

CAUTION:
CAUTION:Take care when installing the exhaust hanger insulators to prevent damage.
NOTE:
NOTE:Check the exhaust hanger insulators for damage. Install new exhaust hanger insulators if required.

Item 4 : Catalytic converter to muffler and tailpipe assembly retaining nuts

  1. CAUTION:
    CAUTION:Twisting the exhaust flexible pipe more than two degrees may cause damage resulting in failure.
    NOTE:
    NOTE:Use a pry bar to prevent the exhaust flexible pipe from twisting when installing the catalytic converter to muffler and tailpipe assembly retaining nuts.
    NOTE:
    NOTE:Install a new catalytic converter to muffler and tailpipe assembly gasket and retaining nuts.
    Install the catalytic converter to muffler and tailpipe assembly retaining nuts.

Catalytic Converter - 2.0L Duratorq-TDCi (DW) Diesel > < Catalytic Converter - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: V