!Guide! Exhaust Manifold/Catalytic Converter - MK7 2011

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-Ford Fiesta Zetec JA8  08-13 1.25 petrol

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Misc:

-Manifold assembly studs/nuts should IDEALLY be replaced
-Manifold & exhaust flange gasket NEEDS to be replaced
-You SHOULD use an OEM manifold gasket and an OEM catalytic converter

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-Put the front end on axle stands

-Wire brush & spray penetrating oil onto the 5 exhaust manifold nuts/studs, the 4 heat shield bolts, the 2 O2 sensors, the 2 lower manifold bracket bolts, and the 2 exhaust flange bolts (Ideally leave for 24 hours but wait at least 30 minutes)
 

-Remove the 2 caps covering the windscreen wiper arm nuts
-Remove both of the windscreen wiper arm nuts with a 12mm socket

-Make a small mark on the window wiper arm and on the mounting point so that you can refit the wiper in the exact same position on reassembly (Use a marker or a Stanley knife)
-Fold both of the wipers up off the window and then rock them back and forth to free them from the splines

-Pry the 6 clips off from the front of the plastic cowl panel grille with a small flathead screwdriver and then pull the panel off the car

-Remove the 2 T30 screws from each headlight unit and pull the top of the headlights out of position by a few inches

-Now that you have access to the 10mm bolt either side of the car that secures the lower cowl panel, remove them
-Locate the last 2 10mm bolts for the lower cowl panel and remove them
-Remove the lower cowl panel from the car
 

-Unplug the upstream and downstream O2 sensor electrical connectors
 

-Remove the 4 10mm bolts for the manifold heat shield (Use heat & cold or cut them off if they are badly rusted)
-Lift the heat shield off the manifold (feed the top stream O2 sensor through the hole in the heat shield)

-Remove both of the O2 sensors using a 22mm spanner (Clean the nuts & thread with a wire brush)

-Spray the 5 manifold nuts with penetrating oil once more
-Remove the top middle bolt for the manifold with a 13mm socket (If it is stuck then apply heat & cold)
-Remove the bottom 3 bolts on the manifold with a 15mm deep socket (If they are stuck then apply heat & cold)

-Remove the top 2 bolts on the manifold with a 15mm socket (If they are stuck then apply heat & cold)
-Free the mating surfaces if they are stuck together (Take a note which way around the gasket needs to sit)
-Remove the 4 E8 manifold studs if they are still in the head
-If you aren't replacing the 4 studs/nuts and the bolt then clean them all up really well with a wire brush

-Remove the 2 exhaust flange nuts with a 15mm socket (Use heat & cold or cut them off if they are badly rusted) (Wire brush the nuts if you are reusing them)
-Free the mating surfaces if they are stuck together

-Remove the 2 10mm bolts on the lower manifold bracket
 

-Put a TROLLEY jack under the engine oil sump and jack up the engine by a few millimetres (Use a piece of wood on the jack point so you do not damage the sump)

-Pull up from the expansion tank to pull it free from its 3 mounting points, and pull it away from the right hand side engine mount

-Spray all of the bolts on the mount with penetrating oil and clean them with a wire brush

-Unbolt the central 18mm bolt that is securing the engine mount bracket to the mount itself

-Unbolt the 2 15mm bolts that are securing the engine mount bracket to the engine block

-Remove the engine mount bracket (Adjust the jack height if the bracket is stuck on the studs)

-Wire brush 2 nuts and the bolt if you aren't replacing them

-Check that the TROLLEY jack is still secure and that the wheels are all pointing straight
-Use a light duty ratchet strap and attach it to the cast anchor point above the alternator and a solid part of the bonnet latch assembly
-Tighten the ratchet until the front of the engine is butted up against the radiator (Keep checking the TROLLEY jack to make sure that it is still safely supporting the engine as the engine moves forward)
-Lower the jack by about 2 inches (Preferably replace the jack with a secure stand at this point)

-Unfasten the 2 8mm bolts on the window wiper linkage
-Unfasten the 10mm bolt on the window wiper linkage
-Pull the window wiper linkage forward and turn it sideways so that it is not obstructing access behind the engine


-Pull the manifold up until the manifold flange is level with the recess where the cowl panel was previously
-Turn the manifold 180 degrees by making use of this recess
-Pull the manifold assembly fully out of the engine bay
 

-Clean up the mating surface for the existing exhaust flange and the manifold mating surface on the engine with brake cleaner and a BRASS brush


-Optionally mask up the flange mating surfaces and O2 sensor ports and give the full assembly 3 coats of VHT paint
-Optionally remove the manifold bracket. Spray the 2 15mm bolts with penetrating oil and then remove them. Wire wheel the bracket, degrease, and spray it with 3 coats of VHT paint (Wire brush the bolts too)
-Remove the masking tape on the O2 sensor ports & mating surface of the new manifold

-Reinstall the manifold bracket with copper anti seize on the 2 15mm bolts @ 51Nm

-Turn the new manifold so that it is facing 180 degrees away from where it needs to sit on the engine
-Lower the manifold and then turn it 180 degrees once the manifold flange is level with the recess for the cowl panel
-Lower the manifold the rest of the way down

-Reinstall the 4 E8 manifold studs @ 20Nm, and then 55Nm (Use copper anti seize on the threads)
-Orient the new gasket so that it is facing the same way as the gasket that you previously removed. Position it between the manifold and the engine block. (Don't use exhaust paste)
-Fasten the middle top bolt with a 13mm socket @ 20Nm (Use copper anti seize on the threads)
-Fasten the bottom left, bottom right, top left, top right 15mm nuts all @ 20Nm (Use copper anti seize on the nuts)
-Re-torque the bolt and these nuts in the same order @ 55Nm

-Reinstall the upstream and downstream O2 sensors with a 22mm spanner until they are a quarter turn past tight (Use copper anti seize on the threads) (Make sure that you match the correct coloured sensor with the correct coloured connector)
-Feed the upstream O2 sensor through the heat shield
-Clip both of the O2 sensor pigtail connectors in

-Fasten the 4 10mm bolts into the heat shield @ 10Nm (Preferably use new bolts) (Use copper anti seize on the threads) (Make large washers out of aluminium if the heat shield has started to perish)
 

-Fasten the 2 10mm exhaust manifold bracket bolts @ 24Nm (Preferably use new bolts) (Use copper anti seize on the threads)

-Engage the flex pipe studs towards the exhaust flange and leave them for now

-If any part of the manifold assembly or bracket has scratched then spray it with VHT paint

-Reposition the engine onto a TROLLEY jack if it is not already on one (use wood)

-Check that the TROLLEY jack is secure and that the wheels are all pointing straight
-Unfasten the ratchet strap

-Push the engine back until it is in its correct position (Check that the trolley jack is secure whilst you do this)
 

-Fasten the central 18mm engine mount bolt to the engine mount bracket and nip it up
-Raise the engine until it is level with the engine mount bracket

-Nip up the 15mm nuts on the engine mount bracket
-Torque the 15mm nuts @ 55Nm
-Torque the 18mm bolt @ 80Nm
-Lower the engine and remove the trolley jack
 

-Clip the expansion tank back onto its mounts

 
-Apply a thin layer of exhaust paste to either side of the gasket and position it on the flange

-Fasten the 2 15mm exhaust flange bolts @ 48Nm (Preferably use new nuts) (Use copper anti seize on the nuts)

-Reposition the window wiper linkage

-Fasten the 2 8mm bolts on the window wiper linkage @ 15Nm
-Fasten the 10mm bolt on the window wiper linkage @ 23Nm (Optionally fill the recess above this bolt with RTV gasket to stop the water from pooling in it and causing rust)
 

-Reposition the lower cowl panel and fasten the 4 bolts @ 10Nm
-Reposition the headlights and nip up the 2 T30 screws on each headlight

-Reposition the top cowl panel grill and secure it with the 6 clips (Squish the slips slightly to give them a tighter fit)

-Position each wiper arm onto the car (line up the mark on the arms with the mark on the receiving end)

-Tighten both of the 12mm nuts for the wiper arms @ 20Nm
-Reinstall both of the caps

-Run the engine at idle for 5 minutes
-Increase the RPM to 2,500 for 2 minutes
-Let it cool down for 30 minutes

-Lower the car back down

-Go for a drive and get the engine very hot. Make sure the exhaust sounds good, and that there is no exhaust leaks.

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Useful sources:

How to Replace a Ford Fiesta Catalytic Converter

2011 Ford Fiesta catalytic converter replacement

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