Congratulations on your purchase of the COBB Tuning Ford Fiesta Cat-Back Exhaust System! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
IMPORTANT! Installing this kit will require custom tuning or utilizing an appropriate Stage Power Package map if you have a matching mechanical configuration. Please consult with COBB or an authorized ProTuner in your area if you have any questions!
Sawzall or other cutting tool to remove factory exhaust.
Removing Factory Exhaust
The stock exhaust is one piece, so you can either remove the rear subframe of the car in order to get it off of the car, or (as our instructions will show) you can cut it in a way that an exhaust shop can add a flange later (if you would ever want to put it back on/sell etc.) and it will make removing the entire exhaust significantly easier and less time consuming.
First thing, get the car jacked up on a flat level area.
With the car up in the air, we’re going to first use the Sawzall to cut the factory exhaust out of the car. This is by far the fastest and easiest way to remove the exhaust. You’ll want to cut the exhaust somewhere in the region marked below, preferably on a straight section of the pipe. Make sure to use eye protection while cutting!
After the cut is made, use your ratched and a 13mm deep socket to remove the four 13mm nuts holding the mid-chassis brace to the vehicle, once removed set it aside for reinstallation later.
With the brace removed, use a 15mm box wrench to break loose the nuts that secure the downpipe to the exhaust system.
With the connection to the downpipe loose, carefully remove the front portion of the stock exhaust by pulling the hanger rods out of the rubber bushings (this is where some silicone lubricant or exhaust pliers can be a big help).
With the front section removed repeat the same process with the rear section.
Installation of the COBB Exhaust System
If not used during removal, a little bit of silicone lubricant used now can help the installation go much easier.
Reusing the metal gasket on the stock downpipe or using a COBB replacement gasket on aftermarket downpipes, start off by fitting the forward pipe into the exhaust hanger bushings and onto the downpipe and loosely installing the factory 15mm nuts to help hold it in place.
Working your way back, loosely install the pipe going over the rear subframe and loosely bolt it up to the forward pipe using the provided hardware and gaskets.
Now loosely install the rear section. Wiggle it around to make sure it is settled in the hangers and centered how you want it in relation to the rear bumper.
With the exhaust lined up how you want, tighten up the flanges starting in the front. Keep in mind they not be perfectly matched up visually and that is normal, it's usually due to the need to line things up for aesthetics and slight differences in bumper/hanger positioning car to car.
Once it's all tightened down reinstall the factory chassis brace using a 13mm socket and the factory hardware.
Lower your car off the jack stands and go out and enjoy!