Ford Focus Service Manual: Muffler and Tailpipe

Removal

NOTE:

The production muffler and tailpipe assembly is one-piece construction. The service muffler and tailpipe is 3-piece construction for Partial Zero Emissions Vehicle (PZEV) and 2-piece construction for non-PZEV . It is necessary to cut the production exhaust system to enable the service sections 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.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section  100-02.

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

   Support the exhaust flexible pipe with a support wrap or suitable splint.

Partial Zero Emissions Vehicle (PZEV)

1. Remove the 2 exhaust flexible pipe-to-muffler and tailpipe assembly nuts.
   • Discard the nuts and gasket.

Non-Partial Zero Emissions Vehicle (PZEV)

1. Remove the 2 catalytic converter-to-muffler and tailpipe nuts.
   • Discard the nuts and gasket.

All vehicles

1. Detach the tailpipe and muffler assembly from the 2 front exhaust hanger isolators.

1. Cut the exhaust system as indicated in the illustration.

1. Detach the 2 exhaust hanger isolators and remove the front muffler section.

1. Detach the exhaust hanger isolator and remove the rear muffler section.

Installation

All vehicles

NOTICE: The exhaust hanger isolators are constructed from a special material. Use only the correct specification exhaust hanger isolators or damage to the exhaust system may occur.

NOTE:

Check the exhaust hanger isolators for damage and fatigue. Install new exhaust hanger isolators as required.

1. NOTE:

   Do not tighten the service clamp at this time.

   Assemble the front muffler service section and service clamp.

1. Position the rear muffler service section and attach the rear exhaust hanger isolator.

1. NOTE:

   Do not tighten the service clamp at this time.

   Using a service clamp, attach the front muffler service section assembly to the rear muffler service section.

   • Attach the 4 exhaust hanger isolators to the front muffler service section assembly.

1. Tighten the service clamps to 47 Nm (35 lb-ft).

Non-PZEV

1. Using a new gasket, attach the catalytic converter-to-muffler and tailpipe assembly and install the 2 new nuts.
   • Tighten to 47 Nm (35 lb-ft).

PZEV

1. Using a new gasket, attach the exhaust flexible pipe-to-muffler and tailpipe assembly and install the 2 new nuts.
   • Tighten to 47 Nm (35 lb-ft).

All vehicles

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

   Remove the exhaust flexible pipe support.