GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| High Temperature Nickel Anti-Seize Lubricant XL-2 | ESE-M12A4-A |
GENERAL SPECIFICATIONS
TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| Exhaust manifold-to-Y-pipe studs (gasoline engines) | 45 |
| Exhaust manifold-to-Y-pipe nuts (gasoline engines) | 40 |
| LH catalytic converter-to-RH catalytic converter clamp nuts (4.6L engines) | 55 |
| Turbocharger-to-exhaust inlet pipe clamp nut (6.0L) | 30 |
| Y-pipe-to-converter nuts (gasoline engines) | 40 |
| Catalytic converter-to-muffler clamp nuts | 40 |
| Bracket and insulator nuts and bolt | 20 |
| Rear bracket and insulator-to-outlet pipe clamp screw | 12 |
| Exhaust inlet pipe-to-catalytic converter bolts | 47 |
| Exhaust gas recirculation (EGR) cooler clamp | 6 |
| Exhaust inlet pipe-to-exhaust manifold nuts | 27 |
TORQUE SPECIFICATIONS
The exhaust system will vary between engine, transmission and vehicle models.
| WARNING | The normal operating temperature of the exhaust system is very high. Never attempt to repair or install any new 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. |
| CAUTION | Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber. |
| CAUTION | Oil or greased-based lubricants on the isolators may cause the exhaust hanger isolator to separate from the exhaust hanger bracket during vehicle operation. |
Note. Exhaust fasteners are of a torque prevailing design. Use only new fasteners with the same part number as the original. Torque values must be used as specified during reassembly to make sure of correct retention of exhaust components.
Use caution when removing a catalytic converter, support the catalytic converter near the rear outlet. Make sure not to damage the manifold output flare, the converter inlet flare or the studs.
During installation, clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare, as well as the mating surfaces of the catalytic converter and the inlet pipe. Support the catalytic converter near the rear outlet. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.
Apply anti-seize lubricant to the threads of the heated oxygen sensors (HO2S) before installation.
The exhaust system consists of the parts shown in the following illustrations and tables.
Scheme 1
Scheme 2
Scheme 3
Scheme 4
Special Tool(s)
SPECIAL TOOLS Exhaust Back Pressure Gauge 309-D002 (D95L-6000-A) or equivalent Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)
Scheme 5
Scheme 6
Inspection and Verification
- Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle to duplicate the condition.
- Visually inspect the components of the exhaust system and related controls that may affect exhaust gas quality or loss of power.
- Visually inspect for obvious signs of mechanical damage. Refer to the following «VISUAL INSPECTION CHART»(/ford/cutaway-e350/2004-2007/remont/exhaust/#exhaust-system) . VISUAL INSPECTION CHART Mechanical Exhaust pipe pinched or crushed Damaged muffler Broken or damaged exhaust hanger brackets Damaged catalytic converter Cracked exhaust manifold Dirty engine air cleaner Loose or damaged heat shields
- Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to specification.
- If the fault is not visually evident, determine the symptom. GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/exhaust/#exhaust-system__symptom-chart) .
Symptom Chart
| Condition | Possible Sources | Action |
|---|---|---|
| Rattle, squeaks or buzz type noise - from the bottom of vehicle | Loose or damaged heat shield | INSPECT the exhaust system for loose or missing heat shields or foreign material trapped between the heat shields and the exhaust system components. If any heat shields are loose, INSTALL either worm gear clamp FOTZ-5A231-A or W705949-S300 and tighten to 7 Nm (62 lb-in). If the heat shields are missing, INSTALL new heat shields or exhaust system components as necessary. If a rattle, noise or buzz condition persists, INSTALL a new heat shield or component as necessary. |
| Loose or damaged exhaust isolators | CHECK exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. | |
| Damaged exhaust isolator hanger bracket | INSPECT the exhaust system components for damage or broken hangers. INSTALL new components as necessary. CHECK for loose or damaged exhaust hanger brackets or fasteners. TIGHTEN bolts to specification or INSTALL new components as necessary. | |
| Loose or damaged catalytic converter or muffler | MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, TAP on the exhaust components to duplicate the noise concern. Lightly TAP on the muffler, then the catalytic converter. Determine if there are loose or broken baffles in the muffler or a loose or broken element in the catalytic converter. REPAIR or INSTALL new components as necessary. | |
| Exhaust grounded to chassis | INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT Exhaust System Alignment . | |
| Drone or clunk type noise - from bottom of vehicle | Loose or damaged exhaust isolators | INSPECT exhaust isolators for wear or damage. INSTALL new isolators as necessary. |
| Exhaust grounded to chassis | INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT Exhaust System Alignment . | |
| Whistles, boom, hum or ticking type noise - noise tends to change as engine warms. Noises are often accompanied by exhaust fumes | Punctures in the muffler Broken, loose or missing exhaust manifold fasteners or gaskets Loose heated oxygen or catalyst monitor sensor | REPAIR as necessary. |
| Exhaust system leak | INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged clamps/fasteners, or broken welds. EXAMINE the chassis for grayish-white or black exhaust soot, which would indicate exhaust leakage at that point. To magnify a small leak, have an assistant hold a rag over the tailpipe outlet, while listening for a leak. REPAIR or INSTALL new components as necessary. | |
| Catalytic converter | MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, TAP on the exhaust components to duplicate the noise concern. Lightly TAP on the muffler, then the catalytic converter. Determine if there are loose or broken baffles in the muffler or a loose or broken element in the catalytic converter. REPAIR or INSTALL new components as necessary. | |
| Exhaust muffler/resonator drain hole enlarged due to corrosion | NOTE: Check with vehicle on the ground, not on a hoist. CONFIRM drain holes are noise source. INSTALL new components as necessary. | |
| Hissing or rushing noise - high frequency sound. Vehicle performance is unaffected | Exhaust system. Exhaust flow through pipes | CHECK the exhaust system for leaks. Using a rubber mallet, TAP on the exhaust components to duplicate the noise concern. Lightly TAP on the muffler, then the catalytic converter. Determine if there are loose or broken baffles in the muffler or a loose or broken element in the catalytic converter. REPAIR or INSTALL new components as necessary. |
| Pinging noise - occurs when exhaust system is hot, engine turned off | Catalytic converter/exhaust system | Cool down pinging is the exhaust system expanding and contracting during heating and cooling. Condition is normal. |
| Vibration - occurs at idle and at low speeds. Also accompanied by clunk or buzz type noise | Loose or damage exhaust isolator | INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. |
| Loose or damaged exhaust isolator hanger brackets | INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as necessary. | |
| Damper broken or out of position if equipped | CHECK for the correct damper orientation. RELOCATE to correct position and tighten nuts to specification. INSPECT for missing or damaged damper. INSTALL new components as necessary. | |
| Exhaust system grounded to chassis | CARRY OUT Exhaust System Alignment . | |
| Vehicle has low or no power - vehicle performance complaint | Exhaust pipe pinched or crushed Damaged catalytic converter Loose obstruction in exhaust | See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles. to test for restricted exhaust. |
| Restricted exhaust (possible frozen condensate in muffler) | CHECK drain holes for foreign material. PARK the vehicle inside to thaw. TEST vehicle for normal operation. If concern is still present, see INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles. | |
| Burning smell - usually occurs at idle, with possible traces of smoke | Foreign material caught in exhaust system Missing heat shields | INSPECT the exhaust system for foreign material or missing heat shields. REPAIR or INSTALL new components as necessary. |
| Odor - described as a sulfur or rotten egg smell | Catalytic converter | At times, a slight sulfur smell is normal for catalytic converters. The cause is the sulfur content in the gasoline being used. ADVISE customer, no repair required. |
| Rich fuel conditions Miss-fire conditions Excessive sulfur content in fuel | See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles. . | |
| Visible rust on surface of exhaust pipes | Catalytic converter/exhaust system | Surface rust is a characteristic of materials used on exhaust system. Exposure to heat or road salt may result in surface rust. INSPECT for perforations. If there are no perforations, condition is normal. |
| NOTE |
|---|
| Check with vehicle on the ground, not on a hoist. |
EXHAUST SYSTEM SYMPTOM CHART
Scheme 7
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting).
- Loosen all fasteners joining the exhaust system components.
- Beginning at the rear of the vehicle, the exhaust system should be aligned to establish the maximum clearance to its surrounding components. Make sure all fit pipes are pushed all the way into the preceding pipe and the pipe notches are fully seated and correctly lined up with the tabs.
- Beginning at the rear of the vehicle, tighten the muffler-to-underbody catalytic converter or converter delete pipe (if equipped) to specification. For vehicles with wheelbases above 138 inches, tighten the muffler-to-extension pipe, followed by the underbody catalytic converter. For additional information, refer to «SPECIFICATIONS»(/ford/cutaway-e350/2004-2007/remont/exhaust/#exhaust-system). Tighten the Y-pipe-to-exhaust manifold nuts in the sequence (Scheme 5): Tighten the RH leg of the Y-pipe. Tighten the outboard exhaust manifold stud-to-Y-pipe nut to 20 Nm (15 lb-ft). Tighten the inboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft). Tighten the LH leg of the Y-pipe. Tighten the outboard exhaust manifold stud-to-Y-pipe nut to 20 Nm (15 lb-ft). Tighten the inboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft), then tighten the outboard exhaust manifold stud-to-Y-pipe nut to 40 Nm (30 lb-ft). Tighten the underbody catalytic converter-to-Y-pipe fasteners to specification. For additional information, refer to «SPECIFICATIONS»(/ford/cutaway-e350/2004-2007/remont/exhaust/#exhaust-system).
- Start the engine and check the exhaust system for leaks.
Material
| Item | Specification |
|---|---|
| High Temperature Nickel Anti-Seize Lubricant XL-2 | ESE-M12A4-A |
MATERIAL SPECIFICATION
Scheme 8
Scheme 9
Scheme 10
Scheme 11
- Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
- Remove the LH turbocharger inlet Y-pipe bolts.
- Remove the RH turbocharger inlet Y-pipe bolts.
- Remove the turbocharger inlet Y-pipe-to-EGR cooler clamp.
- Remove the turbocharger inlet clamp.
- Carefully remove the turbocharger inlet Y-pipe assembly from the vehicle.
Installation
Note. Only tighten the turbocharger inlet Y-pipe fasteners with hand tools.
Note. When installing the turbocharger inlet Y-pipe into, do not bend or twist the flex bellows.
Scheme 12
Scheme 13
Scheme 14
Scheme 15
- If the turbocharger inlet Y-pipe was separated, install the gasket and loosely install the bolts and nuts.
- Position the turbocharger inlet Y-pipe into the vehicle.
- Position the turbocharger inlet clamp.
- Install the metal gasket on the EGR cooler and align the turbocharger inlet Y-pipe to the EGR cooler. Position the clamp.
- Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts, than install the bolts and nuts.
- Tighten the turbocharger inlet clamp.
- Tighten the EGR cooler clamp.
- Make sure the turbocharger inlet Y-pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the nuts to draw the turbocharger inlet Y-pipe to the exhaust manifold. There should be an equal gap spacing between the turbocharger inlet Y-pipe and the exhaust manifold flange at the top and bottom bolts.
- Alternately tighten the turbocharger inlet Y-pipe-to-exhaust manifold bolts.
- If loosened, tighten the turbocharger inlet Y-pipe nuts at the RH to LH joint.
- Check the systems for leaks.
- Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) . .