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Exhaust Y-Pipe - Gasoline Engines: 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.
NOTE: Do not tighten any fasteners until all components are aligned.
    NOTE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS) wiring harness for damage.
    NOTE: LH exhaust Y-pipe-to-exhaust manifold shown in illustration, RH similar.
    Fig 1: Locating Exhaust Y-Pipe-To-Exhaust Manifold Nuts
    G06763170Courtesy of FORD MOTOR CO.
  1. With the help of an assistant, position the exhaust Y-pipe into the vehicle and loosely install 4 new exhaust Y-pipe-to-exhaust manifold nuts.
  2. Loosely install the 2 exhaust Y-pipe-to-catalytic converter bolts.
  3. NOTE: Make sure the exhaust Y-pipe is aligned to provide maximum clearance to adjacent parts.
  4. To seat the LH exhaust Y-pipe-to-exhaust manifold nuts, tighten the nuts in the following sequence.
    • Tighten the lower LH exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in).
    • Tighten the upper LH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
    • Tighten the lower LH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
      Fig 2: Locating Exhaust Y-Pipe-To-Exhaust Manifold Nuts
      G06763170Courtesy of FORD MOTOR CO.
  5. NOTE: Make sure the exhaust Y-pipe is aligned to provide maximum clearance to adjacent parts.
  6. To seat the RH exhaust Y-pipe-to-exhaust manifold nuts, tighten the nuts in the following sequence.
    • Tighten the lower RH exhaust Y-pipe-to-exhaust manifold nut to 20 Nm (177 lb-in).
    • Tighten the upper RH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
    • Tighten the lower RH exhaust Y-pipe-to-exhaust manifold nut to 40 Nm (30 lb-ft).
      Fig 3: Locating RH Exhaust Y-Pipe-To-Exhaust Manifold Nuts
      G06763173Courtesy of FORD MOTOR CO.
  7. Tighten the 2 exhaust Y-pipe-to-catalytic converter bolts.
    • Tighten to 40 Nm (30 lb-ft).
  8. Connect the CMS electrical connector.
  9. Connect the 2 HO2S electrical connectors.