Exhaust Manifold removal on 2003 Ford Focus?

Exhaust Manifold

Removal & Installation

2.0L (VIN 3) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Fan motor electrical connection

   Fan shroud

   Heated Oxygen (HO ₂ S) sensor electrical connection

   Catalytic converter

   Engine oil dipstick tube bracket bolt

   Exhaust manifold heat shield

   Exhaust manifold

To install:

1. Install or connect the following:
   
   
   Exhaust manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).

   Exhaust manifold heat shield. Tighten the retainers to 71-101 inch lbs. (8-11 Nm).

   Engine oil dipstick tube bracket. Tighten the bolt to 71-101 inch lbs. (8-11 Nm).

   Catalytic converter

   HO ₂ sensor electrical connection

   Fan shroud and the fan motor wiring

   Negative battery cable
2. Start the engine and check for leaks.

2.0L (VIN 5) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the oil level indicator and tube.
3. Remove the radiator fan and shroud.
4. Remove the exhaust manifold heat shield lower retaining bolts.
5. Detach the exhaust manifold from the catalytic converter.
6. Lower the vehicle.
7. Remove the exhaust manifold heat shield.
8. Remove the exhaust manifold. Discard the gaskets.

To install:

NOTE

Install new exhaust manifold gaskets.

1. Install the exhaust manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).
2. Install the heat shield and tighten the bolts to 88 inch lbs. (10 Nm).
3. Raise and support the vehicle.
4. Attach the catalytic converter and tighten the bolts to 35 ft. lbs. (47 Nm).
5. Install the radiator fan and shroud.
6. Install the oil level indicator and tube. Tighten the bolts to 15 ft. lbs. (20 Nm).

2.0L (VIN N) And 2.3L (VIN Z) Engine

NOTE

The exhaust manifold is integral to the catalytic converter.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Position the vehicle on a hoist.
3. Relieve the fuel system pressure.
4. Remove the two catalytic converter-to-muffler assembly flange nuts. Discard the nuts.
5. Disconnect the catalyst monitor and the heated oxygen sensor (HO2S) electrical connectors.
6. Remove the two catalytic converter-to-engine bracket bolts.
7. Remove the support bracket bolts.
8. Remove the two lower heat shield screws.
9. Remove and discard the lower two catalytic converter nuts.
10. Lower the vehicle.
11. Disconnect the upper HO2S electrical connector.
12. Disconnect the wiring connector, then remove the bolt and the bracket.
13. Disconnect the fuel lines.
14. Remove the two bolts and the fuel canister assembly.
15. Disconnect the VMV electrical connector.
16. Remove the upper fuel line.
17. Remove the lower fuel line.
18. Remove the two VMV bolts and the VMV.
19. Remove the upper three catalytic converter nuts and studs. Discard the nuts.
20. Remove the PCV hose and the secondary air hose.
21. Disconnect the heat shield from the bulkhead, then remove the heat shield.
22. Position the power steering reservoir aside.
23. Remove the catalytic converter.
    
    NOTE

    If installing a new converter, remove the HO2S and catalyst monitor sensors.
    
    
    
    NOTE

    Make sure to apply anti-seize lubricant to the threads of the sensor before installation.
    
    
    
    NOTE

    Clean the mating surfaces of the exhaust manifold and the catalytic converter mating surfaces.
    
    
    
    NOTE

    Always install new fasteners and gaskets.
    
    
    
    NOTE

    Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.

To install:

1. Position the exhaust manifold and catalytic converter into position, with new gaskets and fasteners.
2. Tighten the nuts to 41 ft. lbs. (55 Nm) in the sequence shown.
   
   
   

   

   Fig. Exhaust manifold/catalytic converter torque sequence-2.0L (VIN N) and 2.3L (VIN Z) engines
3. Install or connect the following:
   
   
   Power steering reservoir

   Heat shield to bulkhead

   PCV hose and secondary AIR hose

   Vapor management valve

   Upper and lower fuel lines

   VMV electrical connector

   Fuel canister

   Fuel lines

   Wiring harness connector

   HO2S connector
4. Raise and support the vehicle.
5. Install or connect the following:
   
   
   2 lower catalytic converter nuts

   2 lower heat shield screws

   Catalytic converter brackets
6. Lower the vehicle.

2.0L (VIN N) Zetec And 2.3L (VIN Z) Engine

NOTE

The exhaust manifold is integral to the catalytic converter.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Position the vehicle on a hoist.
3. Relieve the fuel system pressure.
4. Remove the two catalytic converter-to-muffler assembly flange nuts. Discard the nuts.
5. Disconnect the catalyst monitor and the heated oxygen sensor (HO2S) electrical connectors.
6. Remove the two catalytic converter-to-engine bracket bolts.
7. Remove the support bracket bolts.
8. Remove the two lower heat shield screws.
9. Remove and discard the lower two catalytic converter nuts.
10. Lower the vehicle.
11. Disconnect the upper HO2S electrical connector.
12. Disconnect the wiring connector, then remove the bolt and the bracket.
13. Disconnect the fuel lines.
14. Remove the two bolts and the fuel canister assembly.
15. Remove the vapor management valve (VMV).
16. Disconnect the VMV electrical connector.
17. Remove the upper fuel line.
18. Remove the lower fuel line.
19. Remove the two VMV bolts and the VMV.
20. Remove the upper three catalytic converter nuts and studs. Discard the nuts.
21. Remove the PCV hose and the secondary air hose.
22. Disconnect the heat shield from the bulkhead, then remove the heat shield.
23. Position the power steering reservoir aside.
24. Remove the catalytic converter.
    
    NOTE

    If installing a new converter, remove the HO2S and catalyst monitor sensors.
    
    
    
    NOTE

    Make sure to apply anti-seize lubricant to the threads of the sensor before installation.
    
    
    
    NOTE

    Clean the mating surfaces of the exhaust manifold and the catalytic converter mating surfaces.
    
    
    
    NOTE

    Always install new fasteners and gaskets.
    
    
    
    NOTE

    Do not tighten the fasteners until all components are assembled. Make sure to tighten all fasteners beginning at the front of the vehicle.
25. To install, reverse the removal procedure.
26. Tighten the nuts to 41 ft. lbs. (55 Nm) in the sequence shown.
    
    
    

    

    Fig. Exhaust manifold/catalytic converter torque sequence-2.0L (VIN N) and 2.3L (VIN Z) engines

2.0L (VIN P) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Drive belt

   Heated Oxygen (HO ₂ S) sensor electrical connection

   Exhaust manifold heat shield

   Exhaust Gas Recirculation (EGR) tube

   Power steering pressure hose bracket

   Alternator

   Catalytic converter

   Exhaust manifold

To install:

1. Install or connect the following:
   
   
   Exhaust manifold. Tighten the nuts to 15-18 ft. lbs. (20-24 Nm).

   Catalytic converter. Tighten the nuts to 26-34 ft. lbs. (34-48 Nm).

   Alternator

   Power steering pressure hose bracket

   EGR tube. Tighten the fasteners to 45-62 inch lbs. (5-7 Nm).

   Exhaust manifold heat shield. Tighten the nuts to 45-62 inch lbs. (5-7 Nm).

   HO ₂ S sensor electrical connection

   Drive belt

   Negative battery cable
2. Start the engine and check for leaks.