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Exhaust System Ford Five Hundred I

Exhaust 10 illustrations ~919 words

GENERAL SPECIFICATIONS

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

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Catalyst monitor sensors47
Front catalytic converter bolts40
Front catalytic converter bracket bolt40
Front catalytic converter nuts40
Muffler rear isolator bracket bolts30
Rear catalytic converter bolts40
Rear catalytic converter nuts40
Torca® clamp nut47
Underbody catalytic converter nuts40
Y-pipe isolator bracket bolts30
Front catalytic converter bracket clamp bolt40
Worm gear clamp7

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 exhaust system or removing exhaust components, disconnect all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the HO2S and wiring harness. For additional information, refer to ELECTRONIC ENGINE CONTROLS for location of the HO2S.
CAUTIONDo not use oil or grease-based lubricants on the isolators. They may cause deterioration to the rubber.
CAUTIONOil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to separate from the exhaust hanger bracket during vehicle operation.

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.

The exhaust system

  1. contains dual 2-way catalytic converters and a single 3-way catalytic converter.
  2. has a uniquely designed Y-pipe assembly with a damper.
  3. has 2 upstream HO2S mounted in the exhaust manifolds.
  4. has 2 catalyst monitor sensors mounted after the 2-way catalytic converters.
  5. has a production muffler and resonator assembly which is a one-piece design.

Special Tool(s)

SPECIAL TOOL DESCRIPTION Exhaust Back Pressure Gauge 309-D002 (D95L-6000-A) or equivalent Socket, Exhaust Gas Oxygen Sensor 303-476 (T94P-9472-A)

Scheme 1

Scheme 1: Special Tool(s)
Scheme 1: Special Tool(s)

Scheme 2

Scheme 2
Scheme 2

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 «VISUAL INSPECTION»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) . VISUAL INSPECTION 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
  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/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system__symptom-chart) .

Symptom Chart

ConditionPossible SourcesAction
Rattle, squeaks or buzz type noise - from the bottom of the vehicleLoose 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 worm gear clamp 7L5Z-5A231-AA 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 the Exhaust System Alignment .
Drone or clunk type noise - from bottom of vehicleLoose 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 the Exhaust System Alignment .
Whistles, boom, hum or ticking type noise - noise tends to change as engine warms. Noises are often accompanied by exhaust fumesPunctures 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 unaffectedExhaust 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 offCatalytic 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 noiseLoose or damaged 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.CHECK for the correct damper orientation in this section. INSPECT for missing or damaged damper. INSTALL new components as necessary.
Exhaust system grounded to chassis.CARRY OUT the Exhaust System Alignment .
Vehicle has low or no power - vehicle performance complaintExhaust pipe pinched or crushed.INSTALL new components as necessary.
Damaged catalytic converter. Loose obstruction in exhaust.REFER to INTRODUCTION - GASOLINE article .
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, REFER to INTRODUCTION - GASOLINE article .
Burning smell - usually occurs at idle, with possible traces of smokeForeign material caught in exhaust system.INSPECT the exhaust system for foreign material. REPAIR or INSTALL new components as necessary.
Odor - described as a sulfur or rotten egg smellCatalytic 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. Misfire conditions. Excessive sulfur content in fuel.REFER to the INTRODUCTION - GASOLINE article .
Visible rust on surface of exhaust pipesCatalytic 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.

SYMPTOM

Scheme 3

Scheme 3: Exhaust System Alignment
Scheme 3: Exhaust System Alignment
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Loosen the 4 Y-pipe nuts to the front and rear catalytic converters and the 2 nuts from the Y-pipe to the underbody catalytic converter.
  3. Replace the gasket between the Y-pipe and the underbody catalytic converter.
  4. Shake the exhaust cold end loose and let it hang freely to make sure the isolators are positioned between the 2 hanger rods.
  5. Tighten the 2 nuts from the Y-pipe to the underbody catalytic converter and the 4 nuts from the Y-pipe to the front and rear catalytic converters. Tighten to 40 Nm (30 lb-ft).
  6. Start the engine and check the exhaust system leaks.

Scheme 4

Scheme 4: Torca® Clamp
Scheme 4: Torca® Clamp
  1. Remove the nut from the Torca® clamp.
  2. Grind the spot weld and the tac weld from the Torca® clamp and remove the clamp.
  3. Clean the uneven surface area and position a new Torca® clamp.
  4. Make sure the back of the slot is covered by the clamp and the button is fully seated inside the notch.
  5. Tighten the new Torca® clamp. Tighten to 47 Nm (35 lb-ft).

Scheme 5

Scheme 5: Exhaust System - Exploded View
Scheme 5: Exhaust System - Exploded View
  1. For additional information, refer to the «PROCEDURES»(/ford/five-hundred/i-2004-2007/remont/exhaust/#exhaust-system) .

Material

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

MATERIAL SPECIFICATIONS

Removal and Installation

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 catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine 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.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8
  1. Remove and discard the 2 upper catalytic converter-to-exhaust manifold bolts and gasket for the front or rear catalytic converter. To install, install a new gasket and tighten to 40 Nm (30 lb-ft).
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  3. If removing the front catalytic converter, remove the bracket bolt. To install, tighten to 40 Nm (30 lb-ft).
  4. Disconnect the catalyst monitor sensor electrical connector.
  5. Remove and discard the 2 lower catalytic converter nuts and remove the front or rear catalytic converter. To install, use a new gasket and alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another. Tighten to 40 Nm (30 lb-ft).
  6. If removing the front catalytic converter, inspect the bracket clamp and install a new clamp if necessary. Tighten the clamp bolt to 40 Nm (30 lb-ft).
  7. If installing a new catalytic converter, remove the catalyst monitor sensor. To install, tighten to 47 Nm (35 lb-ft).
  8. To install, reverse the removal procedure. Always install new gaskets and exhaust fasteners.
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 catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTIONDo not use oil-based or grease-based lubricants on the isolators. They may cause deterioration to the rubber.
CAUTIONOil-based or grease-based lubricants on the isolators may cause the exhaust hanger isolators to separate from the exhaust hanger bracket during vehicle operation.

Scheme 9

Scheme 9
Scheme 9
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Position a jack stand to support the muffler and tailpipe assembly.
  3. Loosen the Torca® clamp. To install, tighten to 47 Nm (35 lb-ft).
  4. Disconnect the muffler front and rear isolator.
  5. Disconnect the resonator isolator and remove the muffler and tailpipe assembly.
  6. If necessary, remove the muffler rear isolator bracket bolts, then remove the bracket. To install, tighten to 30 Nm (22 lb-ft).
  7. To install, reverse the removal procedure.

Exhaust Y-Pipe

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 catalytic converter. The temperature of the catalytic converter rises to a high level after only a few minutes of engine operation.
CAUTIONDo not use oil-based or grease-based lubricants on the isolators. They may cause deterioration to the rubber.
CAUTIONOil-based or grease-based lubricants on the isolators may cause the exhaust hanger isolators to separate from the exhaust hanger bracket during vehicle operation.

Scheme 10

Scheme 10
Scheme 10
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove and discard the 4 catalytic converter-to-Y-pipe nuts. To install, alternately tighten the catalytic converter nuts while keeping the exhaust flanges parallel to one another. To install, tighten to 40 Nm (30 lb-ft).
  3. Remove and discard the 2 Y-pipe-to-underbody catalytic converter nuts. To install, tighten to 40 Nm (30 lb-ft).
  4. Remove and discard the Y-pipe-to-underbody catalytic converter gasket. To install, use a new gasket.
  5. Disconnect the Y-pipe isolator and remove the Y-pipe.
  6. If necessary, remove the Y-pipe isolator bracket bolts, then remove the bracket. To install, tighten to 30 Nm (22 lb-ft).
  7. To install, reverse the removal procedure. Always install new gaskets and exhaust fasteners.