CORSA PERFORMANCE 21141 Corsa Xtreme Exhaust Systems Instruction Manual

: June 13, 2024
: CORSA PERFORMANCE

Table of Contents

CORSA PERFORMANCE 21141 Corsa Xtreme Exhaust Systems
Recommended Tools & Supplies
Removal Instructions
Installation Instructions
Before Road Testing
CONTACT
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

CORSA PERFORMANCE 21141 Corsa Xtreme Exhaust Systems

Be sure to review the enclosed instructions prior to beginning the installation process. If you have any questions about the enclosed parts or instructions, or if you encounter a problem during installation:
CALL TECHNICAL SUPPORT: 440.891.0999 or 800.486.0999
TO ACTIVATE YOUR WARRANTY, GO TO: corsaperformance.com/warranty.

COLOR INSTRUCTIONS ARE AVAILABLE BY PART NUMBER ON

corsaperformance.com

NEVER work on a hot exhaust system.

Allow time for the vehicle to cool.

Always wear eye protection

when working under a vehicle.

INSTALL DIFFICULTY

Recommended Tools & Supplies

10mm Socket & Ratchet or Wrench
Grommet Pulling Pliers or Similar
13mm Socket & Ratchet or Wrench
Torque Wrench
15mm Socket & Ratchet or Wrench
Extension for Socket & Ratchet
Soap and Water Solution (for removing and installing Factory Grommets)

Please take time to read and understand these installation instructions.

CORSA recommends that the installation of this system be performed by a qualified service center or professional installer who has the necessary equipment, tools, and experienced personnel.
However, if you decide to perform this installation yourself, the use of an additional person may be required.
WARNING: Never work on a hot exhaust system. Allow time for the vehicle to cool.
Always wear eye protection when working under a vehicle.
This warranty does not extend to damaged or defect in the finish of a product or to any product, that in the opinion of CORSA Performance, has been misused, damaged by accident or negligence, altered, or modified in any way, faulty installation or installed contrary to CORSA installation instructions, or repaired by an unauthorized service facility. Full warranty available on www.corsaperformance.com
Please confirm that all parts are present according to the bill of materials before beginning the installation.
If something is missing, call CORSA Tech Support at 440.891.099 or Toll Free: 1.800.486.0999

2021+ Ford F-150 – Front of Tire Exit

5.0L: 21141, 21141BLK, 21144, 21144BLK, 21147, 21147BLK, 21150,
21150BLK, 21153, 21153BLK, 21156, 21156BLK, 21159, 21159BLK
3.5L: 21162, 21162BLK, 21165, 21165BLK, 21168, 21168BLK

Bill of Materials
1. Head Pipe**| SPORT – 20FF4214 – 145in, 20FF4215 – 157in

XTREME – 20FF4211 – 141in, 20FF4212 – 145in, 20FF4213 – 157in

2. Muffler

| (A) 20FF2038 – SPORT 3.5L 145in+ WB, 20FF2039 – XTREME 5.0L 141in+ WB 20FF2044 – SPORT 5.0L 145in+ WB

(B) 20FF2037 – SPORT 3.5L 141in WB, 20FF2040 – XTREME 5.0L 122in WB 20FF2043 – SPORT 5.0L 141in WB

3. Tail Pipe| (A) 20FF4186 – 141in+ WB, (B) 20FF4209 – 122in WB
4. Tip Assembly| 20FF3010 or 20FF3010BLK|

5. Hardware Kit

| (A) 20FF7083 – With Flange

Contents:

5.1 20FF5008 – Head Pipe Flange

5.2 16CF7001 – 3in Clamp (QTY 3)

5.3 25TU7014 – Isolator

5.4 20FF7082 – Frame Hanger

5.5 20FF7098 – Clip Nut (QTY 2) 5.6 20FF7099 – 5/16in Bolt (QTY 2)

| (B) 20FF7085 – Without Flange**

Contents:

5.2 16CF7001 – 3in Clamp (QTY 3)

5.3 25TU7014 – Isolator

5.4 20FF7082 – Frame Hanger

5.5 20FF7098 – Clip Nut (QTY 2) 5.6 20FF7099 – 5/16in Bolt (QTY 2)

6. Instructions| INS5426 (This Document)|
** A Head Pipe is not required and the Head Pipe Flange is preassembled on the Muffler inlet in Kits: 21141, 21141BLK, 21153, 21153BLK 21162, 21162BLK

If something is missing, call CORSA Tech Support at 440.891.099 or Toll Free: 1.800.486.0999

Removal Instructions

Use a 15mm Socket & Ratchet or Wrench to loosen the Stock Clamp, connecting the Front Section and Rear Section of the Stock exhaust.
Use a 10mm Socket & Ratchet or Wrench to remove the 2 Bolts on each of the Factory Grommets. If the vehicle does not have the Flex Connector shown, the vehicle will have one Factory Grommet and may look different than shown.
Keep the Bolts in a safe place. They will be reinstalled on Installation Step
Keep the Factory Grommet(s) on the Stock Exhaust. They will be installed on the CORSA Exhaust in Installation Step 1.
Locate the Middle Factory Grommets and use a 10mm Socket & Ratchet with an Extension or Wrench to remove the Bolt that attaches it to the Frame. Pull the Factory Grommet toward where the Bolt was attached. This releases a tab from a hole in the Frame.
Above the Rear Axle, locate the Rear Factory Grommet and use a 10mm Socket & Ratchet with an Extension or Wrench to remove 1 the of bolts that attaches it to the Frame. One Bolt is vertical, on the bottom of the Frame. The other is on the inside of the Frame and is horizontal.
Once the first bolt is removed, support the Rear Section of the Factory Exhaust. A second person may be needed to assist with this step. Remove the second Bolt using a 10mm Socket & Ratchet with an Extension or Wrench and gently lower the Rear Section of the Factory Exhaust until it rests on the Rear axle.
To begin removing the Rear Section of the Factory Exhaust, rotate the entire Rear Section so the Stock Tip moves up toward the cavity behind the rear tire. This unlocks the key in the joint where the two Factory Exhaust sections connect. The key is on top of the Factory Exhaust (see image below for location). Once the key is unlocked, the Rear Section can be pulled toward the rear of the vehicle to disconnect from the Front Section. Once disconnected, the Rear Section is removed by moving it forward, over the Rear Axle, and then out from under the vehicle. A second person may be needed to assist with this step.
Use a 13mm Socket & Ratchet or Wrench to loosen the bolts from Stock Flange connection on the Front Section of the Stock exhaust. A second person may be needed to support the Front Section of the Stock exhaust.
After removing the bolts, the Front Section of the Stock exhaust can be removed from under the vehicle.
Keep the Bolts in a safe place. They will be reinstalled on Installation Step 8 or 10.

This concludes the removal of the factory exhaust

WARNING!! DO NOT SKIP THIS STEP WARNING

Apply the supplied Anti-Seize Lubricant to ONLY the threads of the clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially destroy the threads.
After applying anti-seize lubricant, be sure to thoroughly clean your hands. The Anti-Seize lubricant will tarnish stainless steel.
All clamps should be tightened using a properly calibrated Torque Wrench. Using an impact gun will damage the clamp and reduce its ability to effectively seal the joint. It may also cause the joint to separate, thereby causing damage to your exhaust system and to your vehicle.
Before installing, make a line from the end of non-expanded side of the pipes and muffler that is 1⅝in on 2¾in tubing and 1¾in on 3in tubing.
These are CORSA’s nominal joint overlaps. This will help during final adjustment.
Do not be alarmed if the overlap varies slightly when the installation is complete. Any differences are caused by manufacturing variances from vehicle to vehicle and exhaust to exhaust.

Installation Instructions

Using Grommet Pulling Pliers or similar, remove the Factory Grommets from the front of the Factory muffler. Note the orientation for the next step.
The use of a soap and water solution will aid in the removal of the hangers from the Factory Grommets.
Locate the CORSA Front of Tire Tail Pipe. Install the Factory Grommet from Step 1 on to the Front Hanger, as shown. Make sure to orient the Factory Grommet as it was on the Factory exhaust.
NOTE
The remaining Factory Grommets and Factory exhaust are not used with this style CORSA Exhaust installation.
Locate the Clip Nuts from the Hardware Kit.
Next, look under the Passenger Side at Frame Rail. Find the Front Spring Bolt, and then look for the Triangle Hole and Bed Mount. There are two Square and two Round Holes just above the Traingle Hole and within the Bed Mount.
Insert the Clip Nuts into the Square Holes so the Nut is aligned with the Round Hole.
Locate the Frame Hanger and 5/16in Bolts in the Hardware Kit. Thread the 2 Bolts thru the Frame Hanger and into the Clip Nuts previously installed in Step 4.
Use a 13mm Socket & Ratchet or Wrench to tighten the bolts. Torque the bolts to 20 ft-lbs.
If installing a CORSA exhaust with a preassembled Head Pipe Flange on the muffler, skip to Step 10.
If installing a CORSA exhaust with a Head Pipe Flange in the Hardware Kit, locate the Head Pipe. Assemble the Head Pipe Flange onto the Head Pipe, with the chamfer side toward the Flare.
Locate the Head Flange Bolts from Removal
Step 7. A second person may be needed to assist with this step.
Lift the CORSA Head Pipe with assembled Flange into position. Then, carefully start threading the Head Flange Bolts into the Factory Connection.
Then lightly SNUG the Bolts with a 13mm Socket & Ratchet with Extension or Wrench. This joint needs to be loose enough for alignment later but snug enough to support the CORSA Head Pipe and Muffler.
Locate 1 – 3in Clamp from the Hardware Kit and slide it over the Head Pipe. A second person may be needed to assist with this step.
Lift the CORSA Muffler into position and slide the expanded inlet over the Head Pipe outlet. While supporting the CORSA Muffler, confirm the joint overlap and clearances to the vehicle, then SNUG the Clamp with a 15mm Socket & Ratchet or Wrench.
DO NOT FULLY TIGHTEN at this time!
Skip to Step 11.
Locate the Head Flange Bolts from Removal
Step 7. A second person may be needed to assist with this step.
Lift the CORSA Muffler with preassembled Flange into position. While supporting the CORSA Muffler, carefully start threading the Head Flange Bolts into the Factory Connection.
Then lightly SNUG the Bolts with a 13mm Socket & Ratchet with Extension or Wrench. This joint needs to be loose enough for alignment later but snug enough to support the CORSA Muffler.
DO NOT FULLY TIGHTEN at this time!
Slide a 3in Clamp on the CORSA Muffler Outlet.
Locate the Bolts from the Factory Grommet from Removal Step 2. A second person may be needed to assist with this step.
Lift the CORSA Tail Pipe into position and slide the expanded inlet over the Muffler outlet. While supporting the Tail Pipe, carefully thread the Bolts thru the Factory Grommet and into the Factory Clip Nuts in the Frame. Use a 10mm Socket & Ratchet or Wrench to SNUG the 2 Bolts.
Locate the Isolator in the Hardware Kit. Insert the Isolator onto the CORSA Tail Pipe Hanger, then insert the other side of the Isolator on to the Frame Hanger.
The use of a soap and water solution will aid in the installation of the hangers in the grommet.
Use a 15mm Socket & Ratchet or Wrench to SNUG the Clamp connecting the CORSA Muffler and Tail Pipe.
DO NOT FULLY TIGHTEN at this time!
Locate 1 – 3in Clamp from the Hardware Kit. Install the Clamp as shown, with the Clamp Nut on top, facing away from the vehicle frame.
Lift the CORSA Tip Assembly into position and slide the expanded inlet over the Tail Pipe outlet, while supporting the Tail Pipe. Align the CORSA Tip Assembly with the vehicle body line, leaving clearance between the tip and vehicle body.
Use a 15mm Socket & Ratchet or Wrench to SNUG the Clamp connecting the CORSA Tip Assembly and Tail Pipe.
DO NOT FULLY TIGHTEN at this time!
Starting at the Flare Connection, verify the Hangers are properly in the Gromments, the Muffler is close to level, all connections are straight and there is proper clearance around the entire CORSA Exhaust and the Vehicle. Then starting at the Flange Connection, use a Torque Wrench to tighten the clamps to 45ft-lbs and the Factory Hanger Bolts and Flare Connection to Factory specifications.
A second person may be needed to hold the components in the correct position while the clamps are being torqued.

This concludes the installation of the CORSA Exhaust.

Before Road Testing

Start engine, leaving the transmission in park and/or securing the parking brake.
Make sure to look and listen for any unusual noises. Repair problems if needed.
Immediately following the installation of your exhaust system, you may experience a trace of smoke after initial start-up. Do not be alarmed. The smoke is caused by the burning of a small amount of forming oil residue used in the manufacturing process.
It is strongly suggested that the alignment of the components be checked and all clamps re-torqued after road testing the vehicle and allowing the system has fully cooled.
During cold weather start-ups, you may experience an exhaust sound that is deeper and louder in tone than usual. This is temporary and will diminish to normal levels once your engine has reached its normal operating temperature.