Exhaust System Alignment - Gasoline Engines

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Loosen all fasteners joining the exhaust system components.
Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance. Make sure all fit pipes are pushed all the way into the preceding pipe and the notches are correctly lined up with the tabs.

Fig 1: Locating Tab On Exhaust System Pipe Notch
Courtesy of FORD MOTOR CO.
Align the Y-pipe outlet and tighten the exhaust Y-pipe-to-exhaust manifold nuts to specification as follows:
- Tighten the RH leg of the Y-pipe. Tighten the outboard exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in). Tighten the inboard exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
- Tighten the LH leg of the Y-pipe. Tighten the outboard exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in). Tighten the inboard exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
Align the Y-pipe flange to catalytic converter or resonator.
- Tighten the flange to 40 Nm (30 lb-ft).
- If equipped, tighten the resonator Torca® clamp to 48 Nm (35 lb-ft).
Make sure the catalytic converter or resonator button is fully inserted into the button slot on the muffler and tail pipe or, if equipped, the exhaust intermediate pipe; then tighten the catalytic converter or resonator to muffler Torca® clamp or, if equipped, the exhaust intermediate pipe Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 2: Locating Tab On Exhaust System Pipe Notch
  Courtesy of FORD MOTOR CO.
If equipped, make sure the button on the exhaust intermediate pipe is fully inserted into the button slot on the muffler and tail pipe, and tighten the muffler and tail pipe-to-exhaust intermediate pipe Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 3: Locating Tab On Exhaust System Pipe Notch
  Courtesy of FORD MOTOR CO.
Start the engine and check the exhaust system for leaks.