Congratulations on your purchase of the COBB Tuning Focus RS Catback Exhaust! The following instructions will assist you through the installation process. Please read them BEFORE beginning the install to familiarize yourself with the steps and tools needed. If you feel you cannot properly perform this installation, we HIGHLY recommend you take the vehicle to a qualified and experienced automotive technician.
First off park the car in a flat level area and safely lift and support the car.
If you have an older car, spray the exhaust hangers with silicon lube in order to loosen them up for easier exhaust removal later.
Now you'll need to loosen and remove the front clamp where it meets the factory downpipe. Loosen the clamp using a 16mm socket then remove the clamp from the pipe.
Go ahead and unplug the connector from the exhaust valve.
Like the Focus ST, there are two options for removal of the exhaust. One option is to drop the entire rear subframe in order to fish the exhaust out where it goes over the assembly, however this is time consuming and requires a friend and multiple jacks and stands. We opt to cut ours off in the upward slant before it goes over the rear subframe. We typically go back afterwards to add a flange or slip fit to allow it to be reinstalled later if needed. (It also takes up less space in your garage than the entire one piece exhaust assembly which is quite large.
Once the exhaust is separated, start by removing the exhaust hangers for the rear muffler section one at a time, making sure to support it as you go.
Once they're all removed you can swing down the muffler in order to unhook the exhaust where it goes over the rear subframe (depending on where you cut it) and remove it from the car.
With the rear section out of of the way, undo the hangers from the center exhaust section and remove that as well and set it out of the way.
COBB Cat Back Installation
Install the clamp onto the end of the front pipe and slide it back. You may need to stretch out the stock exhaust clamp a little bit in order to get it to fit entirely.
With the front gasket and clamp over the downpipe, roll the mid-pipe and slip the mid-pipe into the hanger making sure to have the slip fit end towards the rear.
Loosely screw down the clamp between the mid-pipe and downpipe.
With an exhaust clamp loose put it over the end of the slip fit and push it away from the connection.
Install the middle section of the exhaust into the front pipe section.
Add another clamp onto the rear section and slide it out of the way of the slip fit.
Work the muffler slip fit on to the mid-pipe, sometimes turning it back and forth can get it up and in place. Make sure it seats all the way to prevent exhaust leaks.
Once the slip fit is seated put it up into the hangers doing one side at a time (the side opposite of where it comes over the subframe is a good place to start so that it can hang somewhat supported by itself when you do the other side.)
Get the exhaust centered and lined up the way you want at the rear bumper.
Double check the positioning of the mid-pipe. Make sure there is enough room between it and the heat shielding to prevent rattles.
Begin tightening the exhaust starting at the front and work to the back. You may need to roll the mid-pipe as you tighten to prevent the clearance from decreasing.
Once everything is tightened and lined up the way you want, plug in the factory connector to the new valve in the COBB Cat Back Exhaust.