OEM 2002 Ford Focus Exhaust Manifold

2002 Ford Focus Exhaust Manifold Parts Q&A

• Q: How to service and repair the exhaust manifold on a Zetec engine on 2002 Ford Focus?

  A: You should start the repair process of a Zetec engine exhaust manifold by elevating the vehicle using a suitable support. Start by detaching the catalyst bracket then disconnecting heated oxygen sensor plugs and finish by lowering the vehicle. Start manifold service and repair by pulling the MAF sensor plug then disconnecting the PCV hose and intake hose thus removing the air cleaner housing from its rubber bushings. Begin the procedure by removing the exhaust gas recirculation (EGR) tube while discarding it before separating the exhaust manifold from both catalyst and cylinder head components. The exhaust manifold should be installed to the cylinder head by using alignment spacers with two outside bolts followed by a new manifold gasket but install it according to the correct catalytic converter sequence to prevent damage and blockages from entering the exhaust manifold. Check the exhaust catalyst cone and EGR threading and clean any foreign material before loosening the bracket to enable easy movement of the catalytic converter. The procedure requires replacement gaskets along with loose fastening of nuts/bolts during this phase. Position the exhaust manifold with new hardware and place the catalytic converter onto it before raising and supporting the vehicle christine in her air. Screw a temporary bolt between the bracket fixture at the converter back and secure the catalytic converter to the exhaust manifold with another bolt and nut. A new catalyst must be used for EGR valve and exhaust catalyst connections followed by loose positioning of the connecting pipe then torquer manufaturer-specified union nuts. Finally attach the catalytic unit. First tighten all bracket bolts on the catalytic converter while installing a new EGR pipe followed by heat shield attachment. Put the catalytic converter bracket into position then fasten it securely before taking out the temporary bolt from the rear catalytic converter bracket. After lowering the vehicle, insert the air filter housing back into the rubber bushings for reattachment. To finish the procedure attach the PCV hose after inserting the mass air flow (MAP) sensor multiplug and put on the intake hose.