Ford Fusion: Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4 / Catalytic Converter. Removal and Installation
Removal
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With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
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Remove the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
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Remove the HO2S.
Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Remove and discard the catalytic converter bolt.
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Remove the catalyst monitor sensor.
Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Remove the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Remove the bolts from the exhaust isolator bracket to the subframe.
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Remove the nuts and the catalytic converter mounting bracket.
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Remove and discard the catalytic convertor bolts.
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Remove the catalytic converter.
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Remove and discard the catalytic converter to TC gasket.
Installation
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Install a new gasket and loosely install the 2 bolts.
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NOTE:
Tighten the catalytic converter bolts in this sequence.
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Position the catalytic converter on the 2 bolts and install the upper bolt.
Torque:
18 lb.ft (25 Nm)
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Tighten the RH catalytic converter bolt.
Torque:
18 lb.ft (25 Nm)
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Tighten the LH catalytic converter bolt.
Torque:
18 lb.ft (25 Nm)
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Install the catalytic converter mounting bracket and the nuts.
Torque:
18 lb.ft (25 Nm)
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Install the exhaust isolator bracket and bolts to the subframe.
Torque:
18 lb.ft (25 Nm)
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Install the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Install the catalyst monitor sensor.
Refer to: Catalyst Monitor Sensor (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Install the HO2S.
Refer to: Heated Oxygen Sensor (HO2S) (303-14A Electronic Engine Controls - 1.5L EcoBoost (118kW/160PS) – I4, Removal and Installation).
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Install the battery.
Refer to: Battery (414-01 Battery, Mounting and Cables, Removal and Installation).
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...
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:
System Operation
System Diagram - Memory Seat
Item
Description
1
Memory Power Seat Motors
2
HS1-CAN
3
PCM
4
BCM
5
HS1-CAN
6
Ignition Switch
7
GWM
8
Memory SET Switch
9
Driver Seat Control Switch
10
MS-CAN
11
DSM
12
MS-CAN
13
DDM
14
Position Sensors
15
Motors
Network Message C..
Removal
Remove the windshield wiper pivot arms.
Refer to: Windshield Wiper Pivot Arm (501-16 Wipers and Washers, Removal and Installation).
On both sides.
Remove the pin-type retainer.
Detach the windshield washer hose coupling and the retainer.
Remove the clips and the cowl panel grille.
Installati..