Attention: Do not deform the catalyst body, avoid strong shocks, bumps and falls, as in these cases, the ceramic core can be damaged. A damaged catalytic converter causes unusual noise and increased concentration of toxic substances in the exhaust gases, and it must be replaced.
Ford Fiestfl/Mazda 121 with 1.3L engine
Removing
Separate the wire connector for the lambda probe. The lambda probe is installed in the exhaust manifold. О Unscrew the two bolts and remove the heat shield from the exhaust manifold.
Remove the five nuts securing the catalytic converter from the exhaust manifold.
Loosen the catalytic converter holder bolts.
Raise and support the vehicle.
Unscrew the bolts of the flange of the rear exhaust pipe and the lower mounting (see picture), remove the catalyst.
Installation
Attention: Do not apply high temperature paste on the parts of the exhaust system before the catalytic converter. Liquid sealant must also not be used, as catalytic converter will be contaminated.
Before installing, clean the exhaust manifold and the front exhaust pipe flange as well as the connection flange with a steel brush. Be sure to use new gaskets, bolts and nuts. To make it easier to unscrew the nuts and bolts of the exhaust system, it is recommended to lubricate them with high-temperature copper paste.
Tighten evenly to 30 Nm. Finally tighten nuts to 40 Nm.
Attention: Nuts and bolts unscrewed during removal (hairpins) must always be replaced. Always lubricate bolts (hairpins) copper paste.
Tighten the catalytic converter fasteners on the upper and lower brackets and then on the rear flange to 50 Nm. О Install the exhaust manifold heat shield and secure it with two bolts.
Install lambda probe connector.
Ford KA
Removing
Remove radiator.
Remove the air filter housing.
Disconnect the lambda probe wire connector. The lambda probe is screwed into the exhaust manifold.
Remove the two heat shield mounting bolts from the exhaust manifold.
Remove the eight nuts securing the exhaust manifold to the cylinder head.
Unscrew the two screws and remove the holder (1) from the cylinder block.
Unscrew the bolt and detach the holder (2) from the gearbox.
Loosen the bolts of the rear exhaust pipe flange and remove the catalytic converter downwards.
Installation
Clean sealing surfaces.
Tighten the catalytic converter on the holder and then on the rear flange to 50 Nm.
Install the radiator.
Fix the exhaust manifold with eight nuts on the block head, tightening them evenly to a torque of 25 Nm. О Install the heat shield for the exhaust manifold and secure it with two bolts.
Plug in the lambda probe plug.
Install the air filter housing.
Ford Fiesta/Mazda 121 with 1.25/1.4L engines and diesel
Removing
Engine 1.25 / 1.4 l: unscrew the twelve bolts and remove the heat shields from the exhaust manifold.
Diesel: pull off the air supply hose from the intake manifold, to do this, release the clamps.
Unscrew the five nuts securing the catalytic converter from the exhaust manifold.
Disconnect the rear exhaust pipe flange.
Engine 1.25/!.4 l: unscrew the two bolts securing the heat shield of the catalytic converter from the bottom of the body and slide the casing off the catalytic converter.
Loosen the screws and remove the catalytic converter.
Loosen the spacer bolts on the gearbox.
Diesel: unscrew one bolt securing the shift bar stabilizer bar from the gearbox.
Pull catalytic converter down. In order to have enough space for removal, it is necessary, if necessary, to slightly press the engine to the side.
Installation
Clean sealing surfaces with a steel brush.
Be sure to use new gaskets, bolts and nuts.
Install the catalytic converter by pressing the engine a little to the side. Lightly tighten all catalytic converter bolts.
Tighten the catalytic converter on the holder and then on the rear flange to 50 Nm.
Install the spacer on the gearbox and tighten the mounting bolt to 50 Nm.
Diesel: Install the gearshift stabilizer bar and tighten its fastening bolt to 50 Nm.
1.25/1.4 liter engine: fit the heat shield to the underbody.
Lower the car.
Tighten the five nuts securing the catalytic converter to the exhaust manifold evenly to 30 Nm. Then tighten nuts to 40 Nm.
1.25/1.4L engine: Install the heat shield on the exhaust manifold.
Diesel: put the air supply hose on the intake manifold and secure it with a clamp.