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.
   

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.
   

1. Remove the nuts and the catalytic converter mounting bracket.
   

1. • Remove and discard the catalytic convertor bolts.
     
   • Remove the catalytic converter.
     

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

Installation

1. Install a new gasket and loosely install the 2 bolts.
   

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)
   2. Tighten the RH catalytic converter bolt.
      Torque: 18 lb.ft (25 Nm)
   3. Tighten the LH catalytic converter bolt.
      Torque: 18 lb.ft (25 Nm)

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

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

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).