Ford Fusion: Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4 / Catalytic Converter. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Powertrain / Exhaust System / Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4 / Catalytic Converter. Removal and Installation

Removal

With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).

Remove the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

Remove the HO2S.
Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Remove and discard the catalytic converter bolt.

Ford Fusion. Catalytic Converter. Removal and Installation

Remove the catalyst monitor sensor.
Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Remove the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Remove the bolts from the exhaust isolator bracket to the subframe.

Remove the nuts and the catalytic converter mounting bracket.

- Remove and discard the catalytic convertor bolts.
- Remove the catalytic converter.

Remove and discard the catalytic converter to TC gasket.

Installation

Install a new gasket and loosely install the 2 bolts.

NOTE: Tighten the catalytic converter bolts in this sequence.
1. Position the catalytic converter on the 2 bolts and install the upper bolt.
  Torque: 18 lb.ft (25 Nm)
1. Tighten the RH catalytic converter bolt.
  Torque: 18 lb.ft (25 Nm)
1. Tighten the LH catalytic converter bolt.
  Torque: 18 lb.ft (25 Nm)

Install the catalytic converter mounting bracket and the nuts.
Torque: 18 lb.ft (25 Nm)

Install the exhaust isolator bracket and bolts to the subframe.
Torque: 18 lb.ft (25 Nm)

Install the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Install the catalyst monitor sensor.
Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Install the HO2S.
Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).

Install the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).

Exhaust System. Diagnosis and Testing

Symptom Chart(s) Symptom Chart: Symptom Chart - Exhaust System Verify the customer concern. Inspect the components of the exhaust system for obvious signs of damage or other mechanical concerns using the following chart...

Muffler and Tailpipe. Removal and Installation

Removal NOTE: Removal steps in this procedure may contain installation details. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation)...

Other information:

Ford Fusion 2013–2020 Service Manual: Valve Stem Diameter. General Procedures

Check NOTE: Refer to the appropriate Section 303-01 for the specification. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. ..

Ford Fusion 2013–2020 Service Manual: Instrument Panel Cluster (IPC) - System Operation and Component Description. Description and Operation

System Operation System Diagram - Gauges Item Description 1 Base/mid-level 2 High-level 3 Base/mid-level 4 High-level 5 Base/mid-level 6 High-level 7 Base/mid-level 8 High-level 9 AWD 10 Temperature 11 Tachometer 12 HS-CAN1 13 IPC 14 GWM 15 PCM 16 HS-CAN3 ..

Parallel Parking

The system detects available parallel parking spaces and steers your vehicle into the space. You control the accelerator, gearshift and brakes. The system visually and audibly guides you into a parallel parking space.

Ford Fusion. Parallel Parking Press the button once to search for a parking space.