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Exhaust System Alignment

WARNING: This page is about a different car, the 2007 Lincoln Mark LT and 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    2. NOTE: Whenever the exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling is loosened, a new exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling must be installed.
    NOTE: Whenever the exhaust intermediate pipe-to-muffler assembly clamp is loosened, a new exhaust intermediate pipe and clamp assembly must be installed.
  2. Loosen all exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe, including the catalytic converter hanger bracket.
  3. Push the muffler and tailpipe assembly forward until the collar on the tailpipe hanger bracket is touching the isolator.
    Fig 1: Pushing Muffler Forward Until Collar On Tailpipe Hanger Bracket Is Touching Isolator
    GF0004180Courtesy of FORD MOTOR CO.
  4. Make sure the button on the muffler and tailpipe assembly inlet pipe is fully inserted into the L-notch on the extension pipe.
    Fig 2: Identifying Button On Muffler Inlet Pipe Is Fully Inserted Into L-Notch On Extension Pipe
    GF0004181Courtesy of FORD MOTOR CO.
  5. Make sure the catalytic converters are fully seated and the notch on the RH catalytic converter is aligned with the button on the LH catalytic converter.
    Fig 3: Aligning Button On LH Catalytic Converter
    GF0004182Courtesy of FORD MOTOR CO.
  6. Tighten the catalytic converter exhaust clamp to 47 Nm (35 lb-ft).
  7. Align the RH catalytic converter (crossover pipe) so that it is parallel to the transmission crossmember. The maximum allowable angle is 1.0 degree.
    Fig 4: Aligning RH Catalytic Converter
    GF0004183Courtesy of FORD MOTOR CO.
  8. Tighten the catalytic converter hanger bracket bolts to 30 Nm (22 lb-ft).
    • Verify the RH catalytic converter (crossover pipe) is still aligned to the transmission crossmember. Realign as necessary.
    Fig 5: Locating Catalytic Converter Hanger Bracket Bolts
    GF0004184Courtesy of FORD MOTOR CO.
  9. If not already tight, tighten the catalytic converter-to-exhaust manifold nuts to specification as follows:
    • Tighten the LH lower converter-to-exhaust manifold nut to 20 Nm (15 lb-ft).
    • Tighten the LH upper converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
    • Tighten the LH lower converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
    • Tighten the RH lower converter-to-exhaust manifold nut to 20 Nm (15 lb-ft).
    • Tighten the RH upper converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
    • Tighten the RH lower converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
  10. Verify the gap between the RH catalytic converter-to-exhaust intermediate pipe is within specification. The maximum allowable gap is 5 mm (0.20 in).
    11. Fig 6: Identifying Gap Between RH Catalytic Converter-To-Exhaust Intermediate Pipe
    GF0004185Courtesy of FORD MOTOR CO.
    NOTE: Whenever the exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling is loosened, a new exhaust Y-pipe - dual catalytic converter-to-exhaust intermediate pipe coupling must be installed.
    Fig 7: Tightening Exhaust Coupler Bolts
    GF0004186Courtesy of FORD MOTOR CO.
  11. Slide the exhaust coupler against the button, then tighten the exhaust coupler bolts to specification. Use the following sequence:
    • Tighten the front nut to 47 Nm (35 lb-ft).
    • Tighten the back nut to 47 Nm (35 lb-ft).
    • Tighten the front nut to 47 Nm (35 lb-ft).
    12. NOTE: Whenever the exhaust intermediate pipe-to-muffler assembly clamp is loosened, a new exhaust intermediate pipe and clamp assembly must be installed.
  12. Tighten the exhaust intermediate pipe-to-muffler and tailpipe assembly exhaust clamp to 47 Nm (35 lb-ft).
  13. Verify the exhaust system is within specification.
  14. Start the engine and check the exhaust system for leaks.
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