Ford Fusion Manuals

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

Removal

  1. With the vehicle in NEUTRAL, position it on a hoist.
    Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
  1. Remove the battery.
    Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Remove the HO2S.
    Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Remove and discard the catalytic converter bolt.
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Remove the catalyst monitor sensor.
    Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Remove the muffler and tailpipe.
    Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Remove the bolts from the exhaust isolator bracket to the subframe.
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Remove the nuts and the catalytic converter mounting bracket.
Ford Fusion. Catalytic Converter. Removal and Installation
    • Remove and discard the catalytic convertor bolts.
    • Remove the catalytic converter.
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Remove and discard the catalytic converter to TC gasket.
Ford Fusion. Catalytic Converter. Removal and Installation

Installation

  1. Install a new gasket and loosely install the 2 bolts.
Ford Fusion. Catalytic Converter. Removal and Installation
  1. 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)
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Install the catalytic converter mounting bracket and the nuts.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Install the exhaust isolator bracket and bolts to the subframe.
    Torque: 18 lb.ft (25 Nm)
Ford Fusion. Catalytic Converter. Removal and Installation
  1. Install the muffler and tailpipe.
    Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Install the catalyst monitor sensor.
    Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. Install the HO2S.
    Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
  1. 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: Brake Pads - 2.7L EcoBoost (238kW/324PS). Removal and Installation


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    Removal NOTICE: During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation...

    Categories

    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.

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