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310 Fuel System > < Exhaust Flexible Pipe - 1.8L Duratec-DOHC (Zetec)

Transit.Tourneo Connect 2002.5 (06.2002-)

Exhaust System - Exhaust Flexible Pipe—1.8L Duratorq-TDDi (Lynx) Diesel, Vehicles With: One-Piece Catalytic Converter and Exhaust Flexible Pipe Transit/Tourneo Connect 2002.5 (06/2002-)
Removal and Installation

General Equipment
Exhaust pipe cutter
Materials
Name
Specification
Grease
SA-M1C9107-A 

Removal

  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel (309-00 Exhaust System, Removal and Installation).

  1. Using an exhaust pipe cutter, cut the exhaust flexible pipe from the catalytic converter in the position shown.

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

  1. NOTE:
    NOTE:Do not fully tighten the exhaust flexible pipe to catalytic converter clamp retaining nut at this stage.
    NOTE:
    NOTE:Make sure that the exhaust flexible pipe locating cut out is aligned with the locating dowel on the catalytic converter.
    Install the exhaust flexible pipe.

  1. NOTE:
    NOTE:Coat the muffler and tail pipe assembly studs with grease.
    NOTE:
    NOTE:Install a new exhaust flexible pipe to muffler and tailpipe assembly gasket and retaining nuts.
    NOTE:
    NOTE:Do not fully tighten the exhaust flexible pipe to muffler and tailpipe assembly retaining nuts at this stage.
    Attach the exhaust flexible pipe to the muffler and tail pipe assembly.
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Install new catalytic converter to exhaust manifold retaining nuts.
    Attach the catalytic converter to the exhaust manifold.
  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. Tighten the catalytic converter to cylinder block retaining bolt.

  1. NOTE:
    NOTE:Remove the cable ties.
    Tighten the exhaust flexible pipe to muffler and tailpipe assembly retaining nuts.

  1. Tighten the exhaust flexible pipe to catalytic converter clamp retaining nut.

  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. Lower the vehicle.

310 Fuel System > < Exhaust Flexible Pipe - 1.8L Duratec-DOHC (Zetec)