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Exhaust System Alignment

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. If equipped, release the 4 fasteners and remove the splash shield.
    Fig 1: Locating Splash Shield Fasteners
    G08341576Courtesy of FORD MOTOR CO.
  3. Loosen all exhaust system component fasteners adjoining the exhaust system.
  4. Loosen the 2 front muffler isolator and bracket assembly bolts.
  5. Loosen the LH isolator cap bolt.
    Fig 2: Locating LH Isolator Cap Bolt
    G06127313Courtesy of FORD MOTOR CO.
  6. Make sure the button on the exhaust intermediate pipe is fully inserted into the L-notch on the muffler and tail pipe assembly inlet pipe.
    Fig 3: Locating L-Notch On Exhaust Intermediate Pipe
    G06171889Courtesy of FORD MOTOR CO.
  7. Make sure the LH catalytic converter is fully seated into the RH catalytic converter up to the stop on the LH catalytic converter.
    Fig 4: Locating LH Catalytic Converter Fully Seated Into RH Catalytic Converter
    G06171890Courtesy of FORD MOTOR CO.
  8. Tighten the RH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
    1. Tighten the RH lower catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    2. Tighten the RH upper catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
      Fig 5: Locating RH Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts
      G06128187Courtesy of FORD MOTOR CO.
  9. Tighten the LH isolator cap bolt.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 6: Locating LH Isolator Cap Bolt
      G06127313Courtesy of FORD MOTOR CO.
  10. Tighten the RH catalytic converter-to-LH catalytic converter Torca® clamp.
    • Tighten to 55 Nm (41 lb-ft).
      Fig 7: Locating Catalytic Converter Torca® Clamp
      G06128189Courtesy of FORD MOTOR CO.
  11. Tighten the LH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
    1. Snug the LH inner catalytic converter-to-exhaust manifold or turbocharger nut.
    2. Tighten the LH outer catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
    3. Tighten the LH inner catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
      Fig 8: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts
      G06128190Courtesy of FORD MOTOR CO.
  12. Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts in the following sequence.
    1. Snug the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.
    2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
    3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
  13. Tighten the exhaust intermediate pipe-to-muffler and tail pipe assembly exhaust Torca® clamp.
    • Tighten to 47 Nm (35 lb-ft).
  14. Tighten the 2 front muffler isolator and bracket assembly bolts.
    • Tighten to 30 Nm (22 lb-ft).
  15. If equipped, install the splash shield and the 4 fasteners.
    Fig 9: Locating Splash Shield Fasteners
    G08341576Courtesy of FORD MOTOR CO.
  16. Start the engine and check the exhaust system for leaks.
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