Ford Fiesta: Exhaust System - 1.6L EcoBoost (132kW/180PS) – Sigma / Muffler and Tailpipe. Removal and Installation

Special Tool(s) / General Equipment

Removal

NOTICE: The production muffler and tailpipe assembly is one-piece construction. The service muffler and tailpipe is 2-piece construction. It is necessary to cut the production exhaust system to enable the service section(s) to be fitted. Before cutting any part of the exhaust system, check that the position of the cut is correct in comparison to the service sections to be installed.

NOTE: Service section part(s) use a service section clamp for assembly.

NOTE: Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.

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. If equipped.
   Remove the 4 nuts and the brace.
   

1. NOTICE: Do not forcibly bend or twist the exhaust flexible pipe. Failure to follow these instructions may cause damage to the flexible pipe.

   NOTE: The 1.6L Duratec muffler and tailpipe assembly shown, 1.6L Ecoboost similar.

   Carefully measure and cut the muffler and tailpipe where shown.
   Use the General Equipment: Air Body Saw

1. Detach the front muffler and tailpipe assembly isolators and remove the 2 catalytic converter-to-muffler and tailpipe assembly nuts. Remove the front muffler and tailpipe section.
   
   • Remove the front muffler and tailpipe section.
     
   • Discard the 2 nuts and gasket.
     
   • Detach the 2 isolators and remove the rear muffler and tailpipe section.
     

Installation

1. Install the rear muffler and tailpipe section and attach the 2 isolators.
   

1. NOTE: If the rear muffler and tailpipe section is being serviced, the rear muffler service part is sized to overlap the front muffler and tailpipe section (shown). If the front muffler and tailpipe section is being serviced, install the service sleeve and clamp.

   NOTE: The 1.6L Duratec muffler and tailpipe assembly shown, 1.6L Ecoboost similar.

   1. Attach the front muffler and tailpipe assembly isolators.
      
   2. Install a new gasket and 2 new catalytic converter-to-muffler and tailpipe assembly nuts.
      Torque: 35 lb.ft (48 Nm)
   3. Install the service clamp.
      Torque: 33 lb.ft (45 Nm)

1. If equipped.
   Install the 4 nuts and the brace.
   Torque: 30 lb.ft (40 Nm)