Exhaust Y-Pipe - Dual Catalytic Converter: Installation

WARNING: This page is about a different car, the 2014 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Clean the mating surfaces of the exhaust manifold outlet or turbocharger flares and the catalytic converter inlet flares.

All vehicles

With the help of an assistant, position the RH catalytic converter into the vehicle and loosely install 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts.

Fig 1: Locating Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts RH
Courtesy of FORD MOTOR CO.
NOTE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.

Loosely install the 2 RH catalytic converter-to-intermediate pipe bolts.

2WD vehicles
Install the transmission insulator and retainer/exhaust bracket assembly and 3 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 2: Locating Transmission Insulator And Retainer/Exhaust Bracket Assembly (2WD)
  Courtesy of FORD MOTOR CO.
Install the transmission crossmember, 4 bolts and 4 nuts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 3: Locating Transmission Crossmember Bolts
  Courtesy of FORD MOTOR CO.
Lower the transmission onto the transmission crossmember and install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.
- Tighten to 103 Nm (76 lb-ft).
  
  Fig 4: Locating Transmission Insulator And Retainer/Exhaust Support Bracket Assembly Nuts
  Courtesy of FORD MOTOR CO.
4WD vehicles
Loosely install the transmission insulator and retainer/exhaust support bracket assembly and the 4 bolts.

Fig 5: Locating Bolts And Transmission Mounting Bracket
Courtesy of FORD MOTOR CO.
Position the transmission crossmember and loosely install the 2 transmission insulator and retainer/exhaust support bracket assembly nuts.

Fig 6: Locating Transmission Insulator And Retainer Nuts
Courtesy of FORD MOTOR CO.
Install the 4 transmission crossmember bolts and nuts.
- Tighten the transmission insulator and retainer/exhaust support bracket assembly and 4 bolts to 90 Nm (66 lb-ft).
- Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).
- Tighten the 2 transmission insulator and retainer/exhaust support bracket assembly nuts to 103 Nm (75 lb-ft).
  
  Fig 7: Locating Transmission Support Crossmember Nuts And Bolts
  Courtesy of FORD MOTOR CO.
All vehicles
Loosely install the LH isolator cap and bolt onto the transmission insulator and retainer/exhaust support bracket assembly.

Fig 8: Locating LH Isolator Cap And Bolt
Courtesy of FORD MOTOR CO.
NOTE: LH side shown in illustration, RH similar.

Install the 2 heat shield bolts into the transmission crossmember.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 9: Locating Heat Shield Bolts And Transmission Crossmember
  Courtesy of FORD MOTOR CO.
4WD vehicles
If equipped, install the transfer case skid plate and 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 10: Locating Skid Plate Bolts
  Courtesy of FORD MOTOR CO.
All vehicles
Slide the LH catalytic converter into the RH catalytic converter up to the stop on the LH catalytic converter and position the LH catalytic converter into place.

Fig 11: Locating LH Catalytic Converter Fully Seated Into RH Catalytic Converter
Courtesy of FORD MOTOR CO.
Loosely install the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts.

Fig 12: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Tighten the 2 new RH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
1. Tighten the RH lower catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
2. Tighten the RH upper catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
  
  Fig 13: Locating Lower And Upper Catalytic Converter-To-Exhaust Manifold Nuts RH
  Courtesy of FORD MOTOR CO.
Tighten the LH isolator cap bolt.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 14: Locating LH Isolator Cap And Bolt
  Courtesy of FORD MOTOR CO.
Tighten the RH catalytic converter-to-LH catalytic converter Torca® clamp.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 15: Locating Catalytic Converter Torca Clamp
  Courtesy of FORD MOTOR CO.
Tighten the 2 new LH catalytic converter-to-exhaust manifold or turbocharger nuts in the following sequence.
1. Snug the LH inner catalytic converter-to-exhaust manifold or turbocharger nut.
2. Tighten the LH outer catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
3. Tighten the LH inner catalytic converter-to-exhaust manifold or turbocharger nut to 40 Nm (30 lb-ft).
  
  Fig 16: Locating LH Catalytic Converter-To-Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.
NOTE: If equipped, do not excessively bend, twist or allow the exhaust to hang from the flexible pipe or damage to the muffler and tailpipe may occur.

Tighten the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts in the following sequence.
1. Snug the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt.
2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm (46 lb-ft).
Connect the 2 CMS electrical connectors.
3.7L, 5.0L and 6.2L
Connect the 2 HO2S pushpins and electrical connectors.
3.5L GTDI
Connect the RH HO2S pushpin and electrical connector.
All vehicles
If equipped, install the splash shield and the 4 fasteners.

3.5L GTDI
Connect the LH HO2S pushpin and electrical connector.
All vehicles
Start engine and check for exhaust leaks.