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!Guide! Cat Back Exhaust Replacement - MK7 2011

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-Ford Fiesta Zetec JA8 1.25 duratec 16v petrol 08-13



-Exhaust flange nuts & all exhaust hangers should IDEALLY be replaced.


-Put the rear end on axle stands

-Wire brush & spray penetrating oil onto the 2 exhaust flange bolts (Ideally leave for 24 hours but wait at least 30 minutes)

-Remove the 2 exhaust flange nuts with a 15mm socket. If they will not come loose then try putting a few cycles of hot, cold, penetrating oil on them. If they still wont come free then cut into the bolt. Be careful not to cut into the studs as they are oftentimes fused onto the flex pipe flange. If you do need to cut the through studs then you will need to cut the studs flush, brace the flexi pipe with wood & clamps and then drill through the studs. (Wire brush the flange nuts if you are reusing them)
-Free the mating surfaces if they are stuck together

-Clean up the mating surface for the existing exhaust flex pipe flange with brake cleaner and a BRASS brush


-Cut the exhaust pipe in front of the muffler
-Cut the exhaust in the middle of the straight pipe
-Cut all of the exhaust hangers off. (Apply silicone grease & pry them off if you are reusing them.)
-Discard the 3 cut out sections of the exhaust



-Use a trolley jack in conjunction with some wood to very slightly take the weight of the rear axle. Do this from the middle of the rigid axle.

-Put a piece of timber or brick under each rear wheel. Something approximating 10-15cm is likely to be sufficient. The axle and therefore wheels only need to drop by about 5-10cm to create access for the exhaust to be pulled out. If the axle lowers too far, it will fully extend the rear brake hoses and put strain on them.

-Spray penetrating oil onto the threads of the lower shock absorber bolts.

-Remove the 15mm bolt at the bottom of each rear shock absorber.

-Slowly lower the trolley jack until the wheels rest on the wood/brick. Make sure that the brake hoses are not fully taut.
-Remove the 4 nuts securing the exhaust chassis brace with a 13mm socket
-Slip the exhaust out from under the car by pushing and rotating it out through the rear end of the car


-Use a trolley jack in conjunction with some wood to very slightly take the weight of the rear axle. Do this from the middle of the rigid axle. 

-Position the coil spring on each side of the axle. Try to orient them so that the coil is positioned at the same rotation as it previously was.

-Raise the jack until each shock absorber eye hole has lined up with the axle. Make sure that each coil spring looks properly seated in position.

-Fasten the 15mm bolt in each shock absorber. Torque to 115Nm.

-Remove the blocks of wood/brick from under the rear wheels.

-Lower the jack down.

-Wiggle each rear spring and check that it looks properly seated.
-Reinstall the exhaust chassis brace with 4 13mm nuts @40Nm (Apply copper grease to the threads)



-Attach all rubber exhaust hangers to the car using silicone grease (Make a small slit in the rubber if you are using new hangers)
-Attach the front section of the exhaust to the hangers with silicone grease
-Apply a thin layer of exhaust paste to either side of the gasket and position it on the flange
-Apply copper grease to the flange nuts and loosely screw them on to the 2 studs (Preferably use new nuts)


-Slide a loose clamp over the back section of the exhaust and apply a small amount of exhaust paste on the receiving end of the pipe
-Slide the exhaust pipe together
-Attach the remaining exhaust brackets to the rubber hangers (Use silicone grease)


-Twist and reposition the exhaust where all of the separate sections meet. Make sure that the exhaust true and it is not going to rub on anything. Make sure that the gaskets are evenly spaced at all sides, and that the pipe is fully seated together.


-Fasten the 2 15mm exhaust flange nuts @ 48Nm
-Fasten the exhaust clamp nuts until they are tight (Apply copper grease to the threads first)

-Run the engine at idle for 5 minutes
-Increase the RPM to 2,500 for 2 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 are no exhaust leaks.


Useful sources:

2014-2019 Ford Fiesta ST Cat-Back Exhaust Installation Guide by Mishimoto




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