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Exhaust System Ford Crown Victoria II

Exhaust 16 illustrations ~680 words
ItemSpecification
Lubricants
High Temperature Nickel Anti-Seize Lubricant XL-2ESE-M12A4-A
Threadlock 262 E2FZ-19554-BWSK-M2G351-AG

EXHAUST SYSTEM GENERAL SPECIFICATIONS

DescriptionNm
Catalytic converter-to-exhaust manifold nuts40
Catalytic converter-to-outlet pipe bolts40
Exhaust clamp nuts45
Muffler-to-tailpipe flange nuts40
Heated oxygen sensor (HO2S)41
Catalyst monitor sensor (CMS)41
Tailpipe hanger bracket-to-frame bolts18
Muffler hanger bracket-to-frame bolts25

EXHAUST SYSTEM TORQUE SPECIFICATIONS

WARNINGThe normal operating temperature of the exhaust system is very high. Never attempt to service any part of the system until it has cooled. Be especially careful when working around the three-way catalytic converter. The temperature of the three-way catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTIONWhen servicing the exhaust system or removing exhaust components, disconnect all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the heated oxygen sensors and wiring harness.
CAUTIONWhen installing new exhaust hanger brackets, make sure to apply threadlock to the hanger-to-frame fasteners.

Note. The production muffler and tailpipe assembly is a one-piece design. The service muffler and tailpipe assembly is serviced with two pieces.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4: Exhaust System
Scheme 4: Exhaust System

Scheme 5

Scheme 5: Inspection and Verification
Scheme 5: Inspection and Verification
  1. Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle to duplicate the condition.
  2. Visually inspect the components of the exhaust system and related controls that may affect exhaust gas quality or loss of power.
  3. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
  4. Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to specification.
  5. If the fault is not visually evident, determine the symptom. GO to «SYMPTOM CHART»(/ford/crown-victoria/ii-1997-2011/remont/exhaust/#exhaust-system) .

Scheme 6

Scheme 6: Symptom Chart
Scheme 6: Symptom Chart

Scheme 7

Scheme 7
Scheme 7

Pinpoint Test

Note. The vehicle can have a lack/loss of power, odor, a noise or a "no start" concern. These concerns may be related to the exhaust system. Carry out the following test, if no trouble codes were stored. This test is for diagnosing the source for these conditions.

Scheme 8

Scheme 8: PINPOINT TEST A: RESTRICTED EXHAUST SYSTEM TEST
Scheme 8: PINPOINT TEST A: RESTRICTED EXHAUST SYSTEM TEST

Scheme 9

Scheme 9: Component Tests
Scheme 9: Component Tests
  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  2. Inspect the exhaust system for loose or missing heat shields or foreign material trapped between the heat shields and the exhaust system components.
  3. If any heat shields are loose, install worm gear clamps. Use one of the following clamps: FOTZ-5A231-A or W705949-S300. Trim off the excess ear of the worm clamp.
  4. If the heat shields are missing, install new heat shields or exhaust system components as necessary.
  5. If a rattle, noise or buzz condition persists, install a new heat shield.
  6. Lower the vehicle.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  2. Loosen all fasteners joining the exhaust system components.
  3. Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance. Make sure all fit pipes are pushed all the way into the proceeding pipe and the notches are correctly lined up with the tabs.
  4. Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional information, refer to «SPECIFICATIONS»(/ford/crown-victoria/ii-1997-2011/remont/exhaust/#exhaust-system) .
  5. Start the engine and check the exhaust system for leaks.

Removal and Installation

CAUTIONDo not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.
CAUTIONOil or grease-based lubricants on the isolators may cause the exhaust hanger isolators to separate from the exhaust hanger bracket during vehicle operation.

Note. The production muffler and tailpipe assembly is a one-piece design. The service muffler and tailpipe assembly is serviced with two pieces.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Turn the air suspension switch off.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  3. Remove the clamp.
  4. Using a suitable exhaust cutter, separate the muffler from the tailpipe.
  5. Detach the insulator and remove the tailpipe.
  6. Detach the insulator and remove the muffler.
  7. To install, reverse the removal procedure.

Catalytic Converter

ItemSpecification
High Temperature Nickel Anti-Seize Lubricant XL-2ESE-M12A4-A

MATERIAL SPECIFICATION

Scheme 12

Scheme 12: Removal and Installation
Scheme 12: Removal and Installation

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Turn the air suspension switch off.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  4. Disconnect the catalyst monitor sensor (CMS) electrical connector.
  5. Remove and discard the catalytic converter-to-exhaust manifold nuts.
  6. Remove the catalytic converter-to-outlet pipe bolts, the flag nuts and the damper, then remove the catalytic converter. Discard the bolts, the flag nuts and the gasket.
  7. If necessary, remove the HO2S and CMS.
  8. Alternately tighten the catalytic converter-to-inlet pipe bolts to specification to draw the flanges together evenly. To install, reverse the removal procedure.

Scheme 16

Scheme 16: Exhaust Heat Shields - Catalytic Converter and Muffler
Scheme 16: Exhaust Heat Shields - Catalytic Converter and Muffler
  1. Turn the air suspension switch off.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/crown-victoria/ii-1997-2011/remont/hoistjack/#jacking-lifting) .
  3. Inspect the exhaust system for loose, damaged or missing heat shields.
  4. If heat shields are loose, install worm clamps. Use one of the following clamps: FOTZ-5A231-A or W705949-S300. Trim off the excess ear of the worm clamp. If the heat shields are missing or damaged, install new heat shields or exhaust system components as necessary.
  5. Lower the vehicle.