Exhaust System Alignment

WARNING: This page is about a different car, the 2005 Ford Pickup. 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 exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe, including the catalytic converter hanger bracket.
Push the muffler 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
Courtesy of FORD MOTOR CO.
Make sure the button on the muffler 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
Courtesy of FORD MOTOR CO.
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
Courtesy of FORD MOTOR CO.
Tighten the catalytic converter exhaust clamp to 48 Nm (35 lb-ft).
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
Courtesy of FORD MOTOR CO.
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.
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).
Verify the gap between the catalytic converter outlet pipe and the muffler inlet pipe is within specification. The maximum allowable gap is 10 mm (0.39 in).

Fig 5: Identifying Gap Between Catalytic Converter Outlet Pipe And Muffler Inlet Pipe
Courtesy of FORD MOTOR CO.
Slide the exhaust coupler against the button, then tighten the exhaust coupler bolts to specification. Use the following sequence:
- Tighten the front nut to 48 Nm (35 lb-ft).
- Tighten the back nut to 48 Nm (35 lb-ft).
- Tighten the front nut to 48 Nm (35 lb-ft).
Fig 6: Tightening Exhaust Coupler Bolts
Courtesy of FORD MOTOR CO.
Tighten the muffler inlet pipe-to-extension pipe exhaust clamp to 48 Nm (35 lb-ft).
Verify the exhaust system is within specification.
Start the engine and check the exhaust system for leaks.