Nadal, a three-time Rogers Cup victor who is back in the hunt for the No. 1 ranking after winning his 10th French Open title this year, will play Canadian teenager Denis Shapovalov, who downed 2009 U.S. Open champion Juan Martin De Potro 6-3, 7-6 (4) in a second-round match on a gusty afternoon.
Shapovalov, who is 18, is the youngest player since Nadal back in 2004 to reach the round of 16 at a Masters Series tournament.
The 18-year-old Shapovalov from Richmond Hill, Ontario, advanced to a quarter-final with France's Adrian Mannarino, who defeated Hyeon Chung of South Korea 6-3, 6-3.
Shapovalov stunned Nadal 3-6, 6-4,7-6 (4) in the third round despite needing a wild card to get into the tournament.
Gael Monfils produced the comeback of the day to beat Kei Nishikori in three sets while Canada's Denis Shapovalov enjoyed the biggest win of his young career by defeating hard-hitting Argentine Juan Martin del Potro 6-3 7-6 (4).
It will be an all-lefty battle between him and Nadal, and with the crowd behind Shapovalov, who knows what's going to happen. He cleaned things up in the last two sets, totaling eight aces with just one double fault in that stretch.
In his first two trips to the service Ferrer has allowed just one point, while he was given seven chances to break in first two attempts of his illustrious rival.
IT was a set of first-serve, first-strike tennis as Nadal won all 11 of his first-serve points, permitting just four points on serve.
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Federer, 36, had never lost in 16 previous meetings with the 35-year-old Ferrer, whom he first defeated 14 years ago at the Vienna Indoor tournament.
Federer will face Spain's David Ferrer in the third round. Nadal was visibly disappointed with himself as he was unable to convert his key opportunities, allowing the Canadian to find his way back and get the win.
It was nearly a repeat of the score line from their match in Toronto where Federer won 6-2 6-0.
However, world number three Roger Federer could take top spot well. Instead, he will now have to win in Cincinnati to overtake the Briton.
Polansky earned a stay of execution after holding serve in the sixth game to make it 5-1, but Federer raced into the next round with a comfortable hold, finishing with an emphatic overhead smash.
Federer promptly went in for the kill, attacking the net and opening up the court to clinch victory with a deft volley.