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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX

309-00A-1 (Sigma) 309-00A-1
.

SECTION 309-00A Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L

Duratec-16V Ti-VCT (Sigma)

VEHICLE APPLICATION: 2011MY Fiesta

CONTENTS PAGE

DESCRIPTION AND OPERATION

Exhaust System (Component Location)............................................................................. 309-00A-2
Exhaust System — Vehicles Built From: 08/2009 (Overview)............................................ 309-00A-4
Exhaust manifold / catalytic converter unit ........................................................................ 309-00A-4
Exhaust system.................................................................................................................. 309-00A-4
Repair note......................................................................................................................... 309-00A-4

REMOVAL AND INSTALLATION

Catalytic Converter............................................................................................................. 309-00A-16
Catalytic Converter — Vehicles With: 5-Speed Manual Transaxle - B5/IB5....................... 309-00A-16
Exhaust Flexible Pipe — 1.25L Duratec-16V (60kW/82PS) - Sigma/1.4L Duratec-16V
(71kW/96PS) - Sigma/1.4L Duratec-16V (70kW/95PS) - Sigma, Vehicles With: 5-Speed
Manual Transaxle - B5/IB5............................................................................................... 309-00A-27
Exhaust Flexible Pipe — 1.6L Duratec-16V Ti-VCT (88kW/120PS) - Sigma, Vehicles With:
5-Speed Manual Transaxle - B5/IB5................................................................................. 309-00A-30

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-2 (Sigma) 309-00A-2
DESCRIPTION AND OPERATION

Exhaust System – Component Location

Vehicles built up to: 08/2009

3
4

E126430

Item Description Item Description

1 Exhaust manifold (gray cast iron) 4 Front muffler
Comments:
2 Catalytic converter 1.6L engine only.
3 Exhaust flexible pipe 5 Final muffler

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-3 (Sigma) 309-00A-3
DESCRIPTION AND OPERATION

Vehicles built from: 08/2009

3 4

E126431

Item Description Item Description

1 Exhaust manifold (stainless steel sheet) 3 Exhaust flexible pipe
2 Catalytic converter 4 Front muffler
5 Final muffler

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-4 (Sigma) 309-00A-4
DESCRIPTION AND OPERATION

Exhaust System — Vehicles Built From: 08/2009 – Overview

Exhaust manifold / catalytic converter so that emissions level V can be achieved. The
unit exhaust gases arrive faster and hotter at the
catalytic converter. This is helped by the optimized
The constantly increasing demands made of material thickness of the exhaust manifold/catalytic
emissions performance and the energy efficiency converter unit. The catalytic converter is heated
of modern motor vehicles require constant up faster.
optimization of all the components used. The gas Use of stainless steel sheet instead of gray cast
flow in the exhaust manifold has been optimized iron achieves a weight reduction of approx. 5 kg.
Fully sheet - exhaust manifold / catalytic converter unit

2
1

E126384

Item Description Item Description

1 Stainless steel exhaust manifold 3 Exhaust flexible pipe
2 Exhaust manifold heat shield 4 Catalytic converter

Exhaust system Exhaust flexible pipes are very fragile and must
not be subjected to any load. They must be
All petrol engines in the Sigma range are equipped secured against twisting and bending during any
with a front muffler to further reduce noise. work on the exhaust system.
Stresses in the exhaust system cause additional
Repair note loads and possible formation of cracks in
components. Care must therefore be taken during
Sealant must never be used upstream of the installation that components are always seated
catalytic converter. without any tension.

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-5 (Sigma) 309-00A-5
REMOVAL AND INSTALLATION

Catalytic Converter
Special Tool(s) Special Tool(s)
204-605 205-775
Separator, Lower Arm Ball Protector, Halfshaft Seal
Joint

E63772 E47098

204-609 General Equipment

Protection Cap, Ball Joint Cable Ties
Gaiter

E75372

Removal
NOTE: Removal steps in this procedure may 3. Loosen: 3 turn(s)
contain installation details.

Vehicles built up to 08/2009

1. Remove the following items:
• Refer to: Heated Oxygen Sensor (HO2S) - x3
Vehicles With: 5-Speed Manual Transaxle
- B5/IB5 (303-14 Electronic Engine
Controls, Removal and Installation).
•
2. 1. Torque: 10 Nm
E103733

4. Refer to: Wheel and Tire (204-04 Wheels and

1 x4 Tires, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
x2
5.

x2
E101805

E102938

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-6 (Sigma) 309-00A-6
REMOVAL AND INSTALLATION
6. 9. Install the Special Tool(s): 204-609

204-609

E102939 E81908

7. 10. WARNING: Be prepared to collect

escaping fluids.
CAUTION: Make sure that all openings
are sealed.
Support the halfshaft. The inner joint must not
be bent more than 18 degrees. The outer joint
must not be bent more than 45 degrees.
Special Tool(s): 204-605

E102188

8. Special Tool(s): 204-605

204-605

E102189
204-605

x2
E103447

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-7 (Sigma) 309-00A-7
REMOVAL AND INSTALLATION
11. Detach and secure the component to one side. 15. 1. 1 - 5:
Torque:
• Stage 1: 20 Nm
• Stage 2: 55 Nm
2. 6:
Torque: 48 Nm

4 1 5

2 3
E104941

12. Remove the following items:

• Refer to: Catalyst Monitor Sensor - Vehicles
With: 5-Speed Manual Transaxle - B5/IB5 6
E102502
(303-14 Electronic Engine Controls,
Removal and Installation).
• Vehicles built 08/2009 onwards
16. Remove the following items:
13. CAUTION: Make sure that the exhaust
• Refer to: Heated Oxygen Sensor (HO2S) -
flexible pipe is not forcibly bent.
Vehicles With: 5-Speed Manual Transaxle
General Equipment: Cable Ties - B5/IB5 (303-14 Electronic Engine
Controls, Removal and Installation).
• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles Built From: 08/2009 (303-14
Electronic Engine Controls - 1.6L
Duratec-16V Ti-VCT (85kW/115PS) -
Sigma, Removal and Installation).

17.

E98634 x4

14. 1. Torque: 48 Nm
2. Torque: 10 Nm

E126588

1 x2
2

E101818

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-8 (Sigma) 309-00A-8
REMOVAL AND INSTALLATION
18. 22.

x4

E126589 E102939

19. Loosen: 3 turn(s) 23.

x3

E103733 E102188

20. Refer to: Wheel and Tire (204-04 Wheels and 24. Special Tool(s): 204-605
Tires, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
21. 204-605

E102189

E102938

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-9 (Sigma) 309-00A-9
REMOVAL AND INSTALLATION
25. Install the Special Tool(s): 204-609 27. Detach and secure the component to one side.

204-609

E81908 E104941

26. WARNING: Be prepared to collect 28. Remove the following items:

escaping fluids. • Refer to: Catalyst Monitor Sensor - Vehicles
CAUTION: Make sure that all openings With: 5-Speed Manual Transaxle - B5/IB5
are sealed. (303-14 Electronic Engine Controls,
Removal and Installation).
Support the halfshaft. The inner joint must not
• Refer to: Catalyst Monitor Sensor - Vehicles
be bent more than 18 degrees. The outer joint
Built From: 08/2009 (303-14 Electronic
must not be bent more than 45 degrees.
Engine Controls - 1.6L Duratec-16V Ti-VCT
Special Tool(s): 204-605 (85kW/115PS) - Sigma, Removal and
Installation).

29.

x3

204-605

E126590

x2
E103447

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-10 (Sigma) 309-00A-10
REMOVAL AND INSTALLATION
30. 2. NOTE: Make sure that a new component is
installed.

x4

E126591

E104969
31. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or 3. Remove the special tool before completely
twisted. installing the halfshaft.
General Equipment: Cable Ties
Special Tool(s): 204-605, 205-775

205-775

E98634

32. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or
twisted.

204-605

x2
x2

E103475

E126593

Installation
Vehicles built up to 08/2009
1. To install, reverse the removal procedure.

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-11 (Sigma) 309-00A-11
REMOVAL AND INSTALLATION
4. 1. WARNING: Make sure that new nuts 7. Torque: 48 Nm
are installed.
Torque: 6 Nm
2. Torque: 6 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm

4
2

E126684

8. Torque: 48 Nm
1
3
E103474

5. Special Tool(s): 204-605

204-605

E126683

9. Torque: 25 Nm

E126685

6. Remove the Special Tool(s): 204-609

E102938

204-609
10. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
11. Lower the Vehicle.
E81908

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-12 (Sigma) 309-00A-12
REMOVAL AND INSTALLATION
12. Torque: 30 Nm 15. Remove the following items:
• General Equipment: Cable Ties

x3

E103733

E126638

Vehicles built 08/2009 onwards

13. CAUTION: Jointing compound must not 16. 1. Torque: 51 Nm
be used forward of the catalytic 2. Torque: 24 Nm
converter.
Torque: 55 Nm

1
4 1 5

2
2 3
E126596

E126594
17. Torque: 25 Nm

14. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or
twisted.
Torque: 48 Nm

x3
x2

E126639 E126590

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-13 (Sigma) 309-00A-13
REMOVAL AND INSTALLATION
18. NOTE: Make sure that a new component is 20. 1. WARNING: Make sure that new nuts
installed. are installed.
Torque: 6 Nm
2. Torque: 6 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm

4
2

E104969

1
19. Remove the special tool before completely
3
installing the halfshaft.
E103474
Special Tool(s): 204-605, 205-775

21. Special Tool(s): 204-605

204-605

205-775

E126685

22. Remove the Special Tool(s): 204-609

204-605

x2
204-609

E103475

E81908

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-14 (Sigma) 309-00A-14
REMOVAL AND INSTALLATION
23. Torque: 48 Nm 28. Torque: 30 Nm

x3

E126684 E103733

24. Torque: 48 Nm 29. Install the following items:

• Refer to: Catalyst Monitor Sensor - Vehicles
With: 5-Speed Manual Transaxle - B5/IB5
(303-14 Electronic Engine Controls,
Removal and Installation).
• Refer to: Catalyst Monitor Sensor - Vehicles
Built From: 08/2009 (303-14 Electronic
Engine Controls - 1.6L Duratec-16V Ti-VCT
(85kW/115PS) - Sigma, Removal and
Installation).
• Refer to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).
E126683
30. Torque: 10 Nm
25. Torque: 25 Nm

x4

E126588

E102938

26. Refer to: Wheel and Tire (204-04 Wheels and

Tires, Removal and Installation).
27. Lower the Vehicle.

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-15 (Sigma) 309-00A-15
REMOVAL AND INSTALLATION
31. Install the following items:
• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles With: 5-Speed Manual Transaxle
- B5/IB5 (303-14 Electronic Engine
Controls, Removal and Installation).
• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles Built From: 08/2009 (303-14
Electronic Engine Controls - 1.6L
Duratec-16V Ti-VCT (85kW/115PS) -
Sigma, Removal and Installation).

All vehicles
32. Refer to: Transmission Fluid Level Check
(308-03 Manual Transmission/Transaxle -
Vehicles With: 5-Speed Manual Transaxle
(iB5), General Procedures).

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-16 (Sigma) 309-00A-16
REMOVAL AND INSTALLATION

Catalytic Converter — Vehicles With: 5-Speed Manual Transaxle

- B5/IB5
Special Tool(s) Special Tool(s)
204-605 205-775
Separator, Lower Arm Ball Protector, Halfshaft Seal
Joint

E63772 E47098

204-609 General Equipment

Protection Cap, Ball Joint Cable Ties
Gaiter

E75372

Removal
NOTE: Removal steps in this procedure may 3. Loosen: 3 turn(s)
contain installation details.

Vehicles built up to 08/2009

1. Remove the following items:
• Refer to: Heated Oxygen Sensor (HO2S) - x3
Vehicles With: 5-Speed Manual Transaxle
- B5/IB5 (303-14 Electronic Engine
Controls, Removal and Installation).
•
2. 1. Torque: 10 Nm
E103733

1 x4

x2

x2
E101805

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-17 (Sigma) 309-00A-17
REMOVAL AND INSTALLATION
4. Refer to: Wheel and Tire (204-04 Wheels and 8. Special Tool(s): 204-605
Tires, Removal and Installation).
Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
5. 204-605

E102189

9. Install the Special Tool(s): 204-609

E102938

6.

204-609

E81908

10. WARNING: Be prepared to collect

escaping fluids.
E102939
CAUTION: Make sure that all openings
are sealed.
7.

E102188

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-18 (Sigma) 309-00A-18
REMOVAL AND INSTALLATION
Support the halfshaft. The inner joint must not 13. CAUTION: Make sure that the exhaust
be bent more than 18 degrees. The outer joint flexible pipe is not forcibly bent.
must not be bent more than 45 degrees. General Equipment: Cable Ties
Special Tool(s): 204-605

E98634

14. 1. Torque: 48 Nm
2. Torque: 10 Nm

204-605

1 x2
x2 2

E103447
E101818

11. Detach and secure the component to one side.

15. 1. 1 - 5:
Torque:
• Stage 1: 20 Nm
• Stage 2: 55 Nm
2. 6:
Torque: 48 Nm

4 1 5

E104941 2 3

12. Remove the following items:

• Refer to: Catalyst Monitor Sensor - Vehicles
With: 5-Speed Manual Transaxle - B5/IB5
(303-14 Electronic Engine Controls, 6
E102502
Removal and Installation).
•

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-19 (Sigma) 309-00A-19
REMOVAL AND INSTALLATION
Vehicles built 08/2009 onwards 20. Refer to: Wheel and Tire (204-04 Wheels and
16. Remove the following items: Tires, Removal and Installation).
• Refer to: Heated Oxygen Sensor (HO2S) - Refer to: Jacking and Lifting (100-02 Jacking
Vehicles With: 5-Speed Manual Transaxle and Lifting, Description and Operation).
- B5/IB5 (303-14 Electronic Engine
21.
Controls, Removal and Installation).
• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles Built From: 08/2009 (303-14
Electronic Engine Controls - 1.6L
Duratec-16V Ti-VCT (85kW/115PS) -
Sigma, Removal and Installation).

17.

x4
E102938

22.

E126588

18.

E102939
x4

23.

E126589

19. Loosen: 3 turn(s)

E102188
x3

E103733

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-20 (Sigma) 309-00A-20
REMOVAL AND INSTALLATION
24. Special Tool(s): 204-605 Support the halfshaft. The inner joint must not
be bent more than 18 degrees. The outer joint
must not be bent more than 45 degrees.
Special Tool(s): 204-605
204-605

E102189

25. Install the Special Tool(s): 204-609

204-605
204-609

E81908
x2
26. WARNING: Be prepared to collect E103447
escaping fluids.
CAUTION: Make sure that all openings 27. Detach and secure the component to one side.
are sealed.

E104941

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-21 (Sigma) 309-00A-21
REMOVAL AND INSTALLATION
28. Remove the following items: 31. CAUTION: Make sure that the exhaust
• Refer to: Catalyst Monitor Sensor - Vehicles flexible pipe is not forcibly bent or
With: 5-Speed Manual Transaxle - B5/IB5 twisted.
(303-14 Electronic Engine Controls, General Equipment: Cable Ties
Removal and Installation).
• Refer to: Catalyst Monitor Sensor - Vehicles
Built From: 08/2009 (303-14 Electronic
Engine Controls - 1.6L Duratec-16V Ti-VCT
(85kW/115PS) - Sigma, Removal and
Installation).

29.

E98634

32. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or
twisted.

x3

x2

E126590

30.
E126593

Installation
Vehicles built up to 08/2009
x4
1. To install, reverse the removal procedure.
2. NOTE: Make sure that a new component is
installed.

E126591

E104969

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-22 (Sigma) 309-00A-22
REMOVAL AND INSTALLATION
3. Remove the special tool before completely 5. Special Tool(s): 204-605
installing the halfshaft.
Special Tool(s): 204-605, 205-775

204-605

205-775 E126685

6. Remove the Special Tool(s): 204-609

204-605
204-609

x2 E81908

E103475
7. Torque: 48 Nm

4. 1. WARNING: Make sure that new nuts

are installed.
Torque: 6 Nm
2. Torque: 6 Nm
3. Torque: 25 Nm
4. Torque: 25 Nm

4
2
E126684

1
3
E103474

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-23 (Sigma) 309-00A-23
REMOVAL AND INSTALLATION
8. Torque: 48 Nm Vehicles built 08/2009 onwards
13. CAUTION: Jointing compound must not
be used forward of the catalytic
converter.
Torque: 55 Nm

4 1 5

E126683

2 3
9. Torque: 25 Nm

E126594

14. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent or
twisted.
Torque: 48 Nm

E102938

10. Refer to: Wheel and Tire (204-04 Wheels and x2

Tires, Removal and Installation).
11. Lower the Vehicle.
12. Torque: 30 Nm
E126639

15. Remove the following items:

x3 • General Equipment: Cable Ties

E103733

E126638

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-24 (Sigma) 309-00A-24
REMOVAL AND INSTALLATION
16. 1. Torque: 51 Nm 19. Remove the special tool before completely
2. Torque: 24 Nm installing the halfshaft.
Special Tool(s): 204-605, 205-775

2 205-775
E126596

17. Torque: 25 Nm

204-605

x2
x3
E103475

20. 1. WARNING: Make sure that new nuts

are installed.
E126590
Torque: 6 Nm
2. Torque: 6 Nm
3. Torque: 25 Nm
18. NOTE: Make sure that a new component is 4. Torque: 25 Nm
installed.

4
2

1
3
E103474
E104969

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-25 (Sigma) 309-00A-25
REMOVAL AND INSTALLATION
21. Special Tool(s): 204-605 24. Torque: 48 Nm

204-605

E126685 E126683

22. Remove the Special Tool(s): 204-609 25. Torque: 25 Nm

204-609

E81908 E102938

23. Torque: 48 Nm 26. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
27. Lower the Vehicle.
28. Torque: 30 Nm

x3

E126684

E103733

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-26 (Sigma) 309-00A-26
REMOVAL AND INSTALLATION
29. Install the following items:
• Refer to: Catalyst Monitor Sensor - Vehicles
With: 5-Speed Manual Transaxle - B5/IB5
(303-14 Electronic Engine Controls,
Removal and Installation).
• Refer to: Catalyst Monitor Sensor - Vehicles
Built From: 08/2009 (303-14 Electronic
Engine Controls - 1.6L Duratec-16V Ti-VCT
(85kW/115PS) - Sigma, Removal and
Installation).
• Refer to: Wheel and Tire (204-04 Wheels
and Tires, Removal and Installation).

30. Torque: 10 Nm

x4

E126588

31. Install the following items:

• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles With: 5-Speed Manual Transaxle
- B5/IB5 (303-14 Electronic Engine
Controls, Removal and Installation).
• Refer to: Heated Oxygen Sensor (HO2S) -
Vehicles Built From: 08/2009 (303-14
Electronic Engine Controls - 1.6L
Duratec-16V Ti-VCT (85kW/115PS) -
Sigma, Removal and Installation).

All vehicles
32. Refer to: Transmission Fluid Level Check
(308-03 Manual Transmission/Transaxle -
Vehicles With: 5-Speed Manual Transaxle
(iB5), General Procedures).

2011MY Fiesta 8/2010 G1062073en

BACK TO CHAPTER INDEX FORD FIESTA 2011MY WORKSHOP REPAIR MANUAL
Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-27 (Sigma) 309-00A-27
REMOVAL AND INSTALLATION

Exhaust Flexible Pipe — 1.25L Duratec-16V (60kW/82PS) -

Sigma/1.4L Duratec-16V (71kW/96PS) - Sigma/1.4L
Duratec-16V (70kW/95PS) - Sigma, Vehicles With: 5-Speed
Manual Transaxle - B5/IB5
General Equipment General Equipment
Air Body Saw Cable Ties

Removal
Vehicles built up to 08/2009 3. General Equipment: Air Body Saw
1. Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
2.

x4

E129182

1704 mm

x2
1
2
E129183

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-28 (Sigma) 309-00A-28
REMOVAL AND INSTALLATION
Vehicles built 08/2009 onwards
4. Refer to: Catalytic Converter - Vehicles With:
5-Speed Manual Transaxle - B5/IB5 (309-00
Exhaust System - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma),
Removal and Installation).

Installation
Vehicles built up to 08/2009
E98634
1. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or
twisted. 2. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or
General Equipment: Cable Ties twisted.
2. Torque: 48 Nm
3. Torque: 45 Nm

x2
x2
2

E129209

3. Remove the following items:

• General Equipment: Cable Ties

E126638

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-29 (Sigma) 309-00A-29
REMOVAL AND INSTALLATION
4. Torque: 40 Nm

x4

E129182

Vehicles built 08/2009 onwards

5. Refer to: Catalytic Converter - Vehicles With:
5-Speed Manual Transaxle - B5/IB5 (309-00
Exhaust System - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma),
Removal and Installation).

2011MY Fiesta 8/2010 G1272821en

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-30 (Sigma) 309-00A-30
REMOVAL AND INSTALLATION

Exhaust Flexible Pipe — 1.6L Duratec-16V Ti-VCT (88kW/120PS)

- Sigma, Vehicles With: 5-Speed Manual Transaxle - B5/IB5
General Equipment General Equipment
Air Body Saw Cable Ties

Removal
Vehicles built up to 08/2009 3. General Equipment: Air Body Saw
1. Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
2.

x4

E129182

1703 mm

x2
1 2
E129184

2011MY Fiesta 8/2010 G1307124en

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-31 (Sigma) 309-00A-31
REMOVAL AND INSTALLATION
Vehicles built 08/2009 onwards
4. Refer to: Catalytic Converter - Vehicles With:
5-Speed Manual Transaxle - B5/IB5 (309-00
Exhaust System - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma),
Removal and Installation).

Installation
Vehicles built up to 08/2009
E98634
1. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or
twisted. 2. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent or
General Equipment: Cable Ties twisted.
2. Torque: 48 Nm
3. Torque: 45 Nm

x2
x2
2

E129210

3. Remove the following items:

• General Equipment: Cable Ties

E126638

2011MY Fiesta 8/2010 G1307124en

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Exhaust System — 1.4L Duratec-16V (Sigma)/1.6L Duratec-16V Ti-VCT TO MODEL INDEX
309-00A-32 (Sigma) 309-00A-32
REMOVAL AND INSTALLATION
4. Torque: 40 Nm

x4

E129182

Vehicles built 08/2009 onwards

5. Refer to: Catalytic Converter - Vehicles With:
5-Speed Manual Transaxle - B5/IB5 (309-00
Exhaust System - 1.4L Duratec-16V
(Sigma)/1.6L Duratec-16V Ti-VCT (Sigma),
Removal and Installation).

2011MY Fiesta 8/2010 G1307124en

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TO MODEL INDEX
309-00B-1 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-1
.

SECTION 309-00B Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel

VEHICLE APPLICATION: 2011MY Fiesta
CONTENTS PAGE

REMOVAL AND INSTALLATION

Catalytic Converter — 1.6L Duratorq-TDCi (DV) Diesel..................................................... 309-00B-2
Exhaust Flexible Pipe......................................................................................................... 309-00B-4
Diesel Particulate Filter (DPF) — 1.6L Duratorq-TDCi (DV) Diesel.................................... 309-00B-6

2011MY Fiesta 8/2010

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TO MODEL INDEX
309-00B-2 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-2
REMOVAL AND INSTALLATION

Catalytic Converter — 1.6L Duratorq-TDCi (DV) Diesel

Removal
NOTE: Removal steps in this procedure may 3.
contain installation details.
1.

x2

E98634

4. Refer to: Jacking and Lifting (100-02 Jacking

and Lifting, Description and Operation).
5. Torque: 25 Nm

E112339

2. Torque: 8 Nm

x3 2

x2

x2 3
1 x2
E112514

x4 4

E112340

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TO MODEL INDEX
309-00B-3 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-3
REMOVAL AND INSTALLATION
6. Torque: 15 Nm

E112341

Installation
1. To install, reverse the removal procedure.

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TO MODEL INDEX
309-00B-4 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-4
REMOVAL AND INSTALLATION

Exhaust Flexible Pipe

General Equipment
Air Body Saw

Removal
4.
1. Refer to: Jacking and Lifting (100-02 Jacking
and Lifting, Description and Operation).
2.

E111891

5.
E98634

3. CAUTION: Make sure that the exhaust

flexible pipe is not forcibly bent.
General Equipment: Air Body Saw x2

10 mm
E111892

Installation
1.
E56697

E98634

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TO MODEL INDEX
309-00B-5 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-5
REMOVAL AND INSTALLATION
2. CAUTION: Make sure that the exhaust
flexible pipe is not forcibly bent.
Torque: 47 Nm

x4

E111893

3. Torque: 47 Nm

x2

E111892

4.

E111891

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309-00B-6 Exhaust System — 1.6L Duratorq-TDCi (DV) Diesel 309-00B-6
REMOVAL AND INSTALLATION

Diesel Particulate Filter (DPF) — 1.6L Duratorq-TDCi (DV) Diesel

Removal

1. Refer to: Catalytic Converter - 1.6L

Duratorq-TDCi (DV) Diesel (309-00 Exhaust
System - 1.6L Duratorq-TDCi (DV) Diesel,
Removal and Installation).

Installation
1.

2011MY Fiesta 8/2010 G1094785en