Exhaust Downpipe - 6.7L Diesel: Installation

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position a new exhaust upper downpipe clamp on the turbocharger.
- Disengage the clamp T-bolt and loosely install it on the turbocharger.

NOTE: Do not tighten the exhaust lower downpipe Torca® clamp at this time.

Insert the exhaust upper downpipe into the exhaust lower downpipe and line up the marks noted during disassembly.
- Do not tighten the Torca® clamp at this time.
  
  Fig 1: Locating Exhaust Upper And Lower Downpipes And Torca® Clamp Orientation Mark
  Courtesy of FORD MOTOR CO.

NOTE: Only hand tighten the exhaust upper downpipe bracket bolt at this time.

Position the exhaust downpipe assembly in the vehicle and hand tighten the exhaust upper downpipe bracket bolt.
- Do not tighten the exhaust upper downpipe bracket bolt at this time.
  
  Fig 2: Locating Exhaust Upper Downpipe Bracket Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Only hand tighten the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts at this time.

Install the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts and hand tighten.
- Do not tighten the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts at this time.
  
  Fig 3: Locating Exhaust Lower Downpipe-To-Catalyst And Particulate Filter Assembly Bolts
  Courtesy of FORD MOTOR CO.
Tighten the exhaust upper downpipe bracket bolt.
- 25 Nm (18 lb-ft).
  
  Fig 4: Locating Exhaust Upper Downpipe Bracket Bolt
  Courtesy of FORD MOTOR CO.
Engage the new exhaust upper downpipe clamp T-bolt and position the clamp as noted during disassembly.
- Tighten to 15 Nm (133 lb-in).

NOTE: Make sure the exhaust upper and lower downpipes are aligned and fully seated together before tightening the Torca® clamp.

Tighten the Torca® clamp.
- 55 Nm (41 lb-ft).
  
  Fig 5: Locating Exhaust Lower Downpipe Torca® Clamp Nut
  Courtesy of FORD MOTOR CO.
Tighten the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 6: Locating Exhaust Lower Downpipe-To-Catalyst And Particulate Filter Assembly Bolts
  Courtesy of FORD MOTOR CO.
Install the RH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
Install the crankcase vent oil separator. For additional information, refer to ENGINE EMISSION CONTROL .
Position the transmission fluid filler tubes and install the 2 bracket bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 7: Locating Transmission Fluid Filler Tubes Bracket Bolts
  Courtesy of FORD MOTOR CO.