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310 Fuel System > < Exhaust System - 2.0L Duratec-RS (Zetec)

Focus RS 2003 (09.2002-)

Exhaust System - Catalytic Converter—2.0L Duratec-RS (Zetec) Focus RS 2003 (09/2002-)
Removal and Installation

Materials
Name
Specification
Grease
SA-M1C9107-A 

Removal
  1. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  1. Raise and support the vehicle.
    For additional information, refer to: Jacking (100-02 Jacking and Lifting, Description and Operation) /
    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. Remove the catalytic converter to muffler retaining nuts.
    • Discard the gasket and nuts.

  1. Remove the catalytic converter lower heat shield.

  1. Remove the catalytic converter to front support bracket retaining bolts (engine shown removed for clarity).

  1. NOTE:
    NOTE:Note the position of the alignment marks on the catalytic converter retaining clamp and turbocharger to aid installation.
    Loosen the catalytic converter to turbocharger retaining clamp (turbocharger heat shield shown removed for clarity).

  1. NOTE:
    NOTE:Support the catalytic converter.
    Remove the catalytic converter rear support bracket retaining bolts.

  1. NOTE:
    NOTE:Support the catalytic converter.
    Remove the catalytic converter to turbocharger retaining clamp and the catalytic converter (turbocharger heat shield shown removed for clarity).

  1. Remove and discard the turbocharger to catalytic converter gasket.

  1. Remove the H02S.

  1. Remove the exhaust heat shield and the catalytic converter upper heat shield.

Installation
  1. Install the exhaust heat shield and the catalytic converter upper heat shield.

  1. Install the H02S.

  1. Install a new turbocharger to catalytic converter gasket.

  1. NOTE:
    NOTE:Do not fully tighten the catalytic converter to front support bracket retaining bolts at this stage.
    Install the catalytic converter to front support bracket retaining bolts (engine shown removed for clarity).

  1. CAUTION:
    CAUTION:Never use jointing compound forward of the catalytic converter.
    CAUTION:
    CAUTION:When installing the catalytic converter make sure that excessive strain is not placed on the exhaust flexible pipe.
    NOTE:
    NOTE:Support the catalytic converter.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter to turbocharger retaining clamp at this stage.
    Install the catalytic converter to turbocharger retaining clamp (turbocharger heat shield shown removed for clarity).

  1. NOTE:
    NOTE:Support the catalytic converter.
    NOTE:
    NOTE:Make sure the support bracket faces are aligned correctly and the support brackets are able to move freely at this stage.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter rear support bracket retaining bolts at this stage.
    Install the catalytic converter rear support bracket retaining bolts.

  1. CAUTION:
    CAUTION:Make sure the catalytic converter and turbocharger mating surfaces are correctly aligned before the catalytic converter exhaust clamp is fully tightened.
    NOTE:
    NOTE:Make sure the locating mark on the catalytic converter retaining clamp and turbocharger are correctly aligned (alignment mark shown from the top for clarity).
    NOTE:
    NOTE:Support the catalytic converter.
    Tighten the catalytic converter to turbocharger retaining clamp (turbocharger heat shield shown removed for clarity).

  1. NOTE:
    NOTE:Support the catalytic converter.
    Tighten the catalytic converter rear support bracket retaining bolts.

  1. NOTE:
    NOTE:Support the catalytic converter.
    Tighten the catalytic converter to front support bracket retaining bolts (engine shown removed for clarity).

  1. Install the catalytic converter lower heat shield.

  1. NOTE:
    NOTE:Coat the catalytic converter studs with grease.
    NOTE:
    NOTE:Install a new gasket and nuts.
    Install the catalytic converter to muffler retaining nuts.

  1. Remove the exhaust flexible pipe support wrap or suitable splint.
  1. Lower the vehicle.

  1. Connect the HO2S electrical connector.

310 Fuel System > < Exhaust System - 2.0L Duratec-RS (Zetec)