TORQUE SPECIFICATIONS
| Description | Nm |
|---|---|
| Bracket-to-catalytic converter bolts | 20 |
| Catalytic converter support bracket-to-transmission bolts | 48 |
| Catalytic converter-to-exhaust manifold nuts | 40 |
| Catalytic converter-to-exhaust manifold studs | 25 |
| Exhaust Y-pipe-to-exhaust intermediate pipe nuts | 40 |
| Exhaust Y-pipe-to-catalytic converter nuts | 40 |
| Torca® clamp | 55 |
TORQUE SPECIFICATIONS
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases through the catalytic converters, a muffler assembly and resonator. Rubber exhaust hanger isolators attach the exhaust system to the mounting hooks.
Catalytic Converter
The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the exhaust gases in order to reduce air pollutants.
The catalyst material inside the catalytic converter consists of a ceramic substrate.
Precautions
| CAUTION | Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel may destroy the catalyst and render the catalytic converter useless. The addition of lead to the catalytic converter may also solidify the catalyst, causing excessive back pressure in the exhaust system and possibly causing engine damage. |
| CAUTION | Extremely high temperatures of 1,100°C (2,012°F) or above due to misfiring or an over-rich fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter. Do not continue to operate the vehicle if the engine is misfiring, there is a power loss, or other unusual operating conditions, such as engine overheating and backfiring. |
The catalytic converter is designed to provide a long life. No maintenance is necessary for the catalytic converter.
Sound Insulators and Shields
Sound insulators and shields, attached to the underbody, protect the vehicle from exhaust system heat and should be inspected at regular intervals to make sure they are not dented or out of position. If a sound insulator and shield is damaged or shows evidence of deterioration, it should be replaced. The sound insulators and shields for the muffler, muffler pipe, resonator and catalytic converter pipe are installed separately.
Special Tools Illustration Tool Name Tool Number Electronic Vibration Analyzer or equivalent 100-F027 (014-00344)
Scheme 1
Inspection and Verification
- Verify the customer concern.
- 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 chart. VISUAL INSPECTION CHART Mechanical Exhaust pipe pinched or crushed Damaged muffler Broken or damaged exhaust hanger brackets Damaged catalytic converter Cracked exhaust manifold 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 - Exhaust System»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) or Go to «Symptom Chart - Noise, Vibration and Harshness (NVH)»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) .
| Condition | Possible Sources | Action |
|---|---|---|
| Vehicle has low or no power - vehicle performance complaint | Exhaust pipe pinched or crushed Damaged catalytic converter Loose obstruction in exhaust | REFER to the Introduction - Gasoline Engines article. |
| Restricted exhaust (possible frozen condensate in muffler) | CHECK drain holes for foreign material. PARK the vehicle inside to thaw. TEST the vehicle for normal operation. If the concern is still present, REFER to the Introduction - Gasoline Engines article. | |
| 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. TEST the system for normal operation after the repair. |
| Odor - described as a sulfur or rotten egg smell | Catalytic converter Excessive sulfur content in fuel | At times, a slight sulfur smell is normal for catalytic converters. The cause is the sulfur content in the gasoline being used. ADVISE the customer no repair is required. |
| Rich fuel conditions Misfire conditions | REFER to the Introduction - Gasoline Engines article. | |
| Visible rust on surface of exhaust pipes | Catalytic converter/exhaust system | Surface rust is a characteristic of materials used on exhaust systems. Exposure to heat or road salt may result in surface rust. INSPECT for perforations. If there are no perforations, the condition is normal. |
Symptom Chart - Exhaust System
Symptom Chart - Noise, Vibration and Harshness (NVH)
Note. Noise, vibration and harshness (NVH) symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of common terms, refer to NOISE, VIBRATION AND HARSHNESS article. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to NOISE, VIBRATION AND HARSHNESS article for the next likely system and continue diagnosis.
| Condition | Possible Sources | Action |
|---|---|---|
| Rattle, squeaks or buzz type noise - from the bottom of the 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 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. TEST the system for normal operation after the repair. |
| Loose or damaged exhaust isolators | VERIFY that the exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. | |
| 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 the bolts to specification or INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| 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. TEST the system for normal operation after the repair. | |
| 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 the bottom of the vehicle | Loose or damaged exhaust isolators | INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. |
| 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 the engine warms. The noises are often accompanied by exhaust fumes | Exhaust system leak | INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged clamps/fasteners, gaskets, sensors or broken welds. EXAMINE the chassis for grayish-white or black exhaust soot, which indicates exhaust leakage at that point. To magnify a small leak, have an assistant hold a shop towel over the tailpipe outlet while listening for a leak. REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair. |
| 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 and 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. TEST the system for normal operation after the repair. | |
| Exhaust muffler/resonator drain hole enlarged due to corrosion | CONFIRM the drain holes are the noise source. INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| 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 and 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. TEST the system for normal operation after the repair. |
| Pinging noise - occurs when exhaust system is hot, engine turned off | Catalytic converter/exhaust system | Cool down pinging is a result of the exhaust system expanding and contracting during heating and cooling. This is a normal condition. |
| Vibration - occurs at idle and at low speeds. Also accompanied by a clunk or buzz type noise | Loose or damaged exhaust isolator | INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair. |
| Loose or damaged exhaust isolator hanger brackets | INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as necessary. TEST the system for normal operation after the repair. | |
| Damper broken or out of position | CHECK for the correct damper orientation in this article. RELOCATE to the correct position and tighten the nuts to specification. INSPECT for missing or damaged damper. INSTALL new components as necessary. TEST the system for normal operation after the repair. | |
| Exhaust system grounded to chassis | CARRY OUT the Exhaust System Alignment . | |
| Engine drumming noise - normally accompanied by vibration | Damaged or misaligned exhaust system | INSPECT the exhaust system for loose or damaged fasteners, Torca® clamps or isolators. CARRY OUT the Exhaust System Alignment . |
| Sputter type noise - noise worse when cold, lessens or disappears when the vehicle is at operating temperature | Damaged or worn exhaust system | INSPECT the exhaust system for leaks or damage. REPAIR as necessary. TEST the system for normal operation after the repair. |
| Thumping noise - from the bottom of the vehicle, worse at acceleration | Misaligned exhaust system | CHECK the exhaust system to chassis clearance. CHECK the exhaust system isolators for damage. REPAIR as necessary. TEST the system for normal operation after the repair. |
| Engine vibration - is felt with increases and decreases in engine RPM | Strain on exhaust system isolators | CARRY OUT the Exhaust System Alignment . REPAIR as necessary. TEST the system for normal operation after the repair. |
| Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency drumming is very RPM dependent | Exhaust system vibration excites the body resonances inducing interior noise | Go to Pinpoint Test A . |
Symptom Chart - Noise, Vibration and Harshness (NVH)
Scheme 2
- A1 CHECK THE EXHAUST SYSTEM Key in START position. Increase the engine RPM until the noise is the loudest. Note the engine RPM. Key in OFF position. Add approximately 9 kg (20 lb) of weight to the exhaust system. First, place the weight at the tail pipe and test. Repeat at the front pipe. Key in START position. Increase the engine RPM and listen for the drumming noise. Note the engine RPM if the noise occurs. Key in OFF position. Using a vibration analyzer (VA), determine the amount of vibration that occurs with the drumming noise. Is the noise/vibration reduced or eliminated, or does the noise/vibration occur at a different RPM? YES : REFER to «Exhaust System Alignment»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) . TEST the system for normal operation. NO : CONDUCT a diagnosis on other suspect systems. REFER to «NOISE, VIBRATION AND HARSHNESS»(/ford/taurus-x/i-2007-2009/remont/oem-general-information/#noise-vibration-and-harshness) article.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Loosen all fasteners joining the exhaust system components.
- 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 preceding pipe and the notches are correctly lined up with the tabs.
- Beginning at the front of the vehicle, tighten all fasteners and clamps to specification. For additional information, refer to «SPECIFICATIONS»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) .
- Start the engine and check the exhaust system for leaks.
Torca® Clamp
- Remove the nut from the Torca® clamp.
- Grind the spot weld and the tac weld from the Torca® clamp and remove the clamp.
- Clean the uneven surface area and position the Torca® clamp.
- Make sure the back of the slot is covered by the clamp and the button is fully seated inside the notch.
- Tighten the Torca® clamp. Tighten to 55 Nm (41 lb-ft).
Scheme 3
| Item | Part Number | Description |
|---|---|---|
| 1 | 14A464 | LH catalyst monitor sensor electrical connector |
| 2 | W710656 | LH catalytic converter support bracket-to-transmission bolts (2 required) |
| 3 | W705443 | LH catalytic converter-to-exhaust manifold nut (4 required) |
| 4 | 5F263 | Gasket |
| 5 | 5G228 | Bracket-to-LH catalytic converter bolt (2 required) |
| 6 | 5E213 | LH catalytic converter |
| 7 | W711133 | LH catalytic converter-to-exhaust manifold stud (4 required) |
| 8 | 5E241 | Gasket |
| 9 | W705443 | Exhaust Y-pipe-to-LH catalytic converter nut |
| 10 | W705443 | Exhaust Y-pipe-to-flange nut (2 required) |
| 11 | 9451 | Gasket |
| 12 | 5G274 | Exhaust Y-pipe |
| 13 | 5A212 | Exhaust intermediate pipe (federal emissions engines only) |
| 14 | 5F262 | Exhaust Y-pipe isolator |
| 15 | 5F262 | Muffler and tailpipe isolator (3 required) |
Scheme 4
| Item | Part Number | Description |
|---|---|---|
| 16 | 5G228 | Bracket-to-RH catalytic converter bolt (2 required) |
| 17 | W705443 | RH catalytic converter-to-exhaust manifold nut (4 required) |
| 18 | 5F263 | Gasket |
| 19 | 5E211 | RH catalytic converter |
| 20 | W711133 | RH catalytic converter-to-exhaust manifold stud (4 required) |
| 21 | W705443 | Exhaust Y-pipe-to-RH catalytic converter nut (2 required) |
| 22 | 9451 | Gasket |
| 23 | 5221 | Torca® clamp |
| 24 | 5K214 | Muffler and tailpipe assembly |
| 25 | 5E243 | Catalytic converter (partial zero emissions vehicle [PZEV] engines only) |
- For additional information, refer to the procedures in this article.
REMOVAL AND INSTALLATION
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Disconnect the catalyst monitor sensor electrical connector.
- Remove the exhaust Y-pipe. For additional information, refer to «Exhaust Y-Pipe»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) .
- Remove the 2 catalytic converter support bracket-to-transmission bolts. To install, tighten to 48 Nm (35 lb-ft).
- Remove the 4 nuts and the LH catalytic converter. Discard the 4 LH catalytic converter nuts and gasket. To install, tighten to 40 Nm (30 lb-ft).
- To install, reverse the removal procedure. Install a new gasket, nuts and studs.
Catalytic Converter - RH
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Remove the exhaust Y-pipe. For additional information, refer to «Exhaust Y-Pipe»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) .
- Remove the RH catalyst monitor sensor. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/taurus-x/i-2007-2009/remont/removal-installation/#electronic-engine-control-system) article.
- Remove the 2 bracket-to-RH catalytic converter bolts. To install, tighten to 20 Nm (15 lb-ft).
- Remove the 4 nuts and the RH catalytic converter. Discard the 4 RH catalytic converter nuts and gasket. To install, tighten to 40 Nm (30 lb-ft).
- To install, reverse the removal procedure. Install a new gasket, nuts and studs.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Remove and discard the 2 exhaust Y-pipe flange nuts. Discard the gasket. To install, tighten to 40 N.m (30 lb-ft).
- Loosen the Torca® clamp nut. To install, tighten to 55 Nm (41 lb-ft).
- Separate the catalytic converter from the muffler and tailpipe and remove the catalytic converter.
- To install, reverse the removal procedure. Always install new gaskets and exhaust fasteners.
- Start the engine and check for exhaust leaks.
| CAUTION | Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber. |
| CAUTION | Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to separate from the exhaust hanger bracket during vehicle operation. |
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Support the muffler and tailpipe with a suitable jackstand.
- Remove and discard the 2 exhaust Y-pipe flange nuts. Discard the gasket. To install, tighten to 40 Nm (30 lb-ft).
- Using soapy water, separate the 3 isolators and remove the muffler and tailpipe assembly from the vehicle.
- To install, reverse the removal procedure. Install a new gasket and nuts. Inspect and replace any isolators damaged or torn during the removal process.
- Start the engine and check for exhaust leaks.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Remove and discard the 4 exhaust Y-pipe-to-LH and RH catalytic converter nuts. Discard the gaskets. To install, tighten to 40 Nm (30 lb-ft).
- Remove and discard the exhaust Y-pipe flange nuts and remove the exhaust Y-pipe. Discard the gasket. To install, tighten to 40 Nm (30 lb-ft).
- To install, reverse the removal procedure. Install new gaskets and nuts.
- Start the engine and check for exhaust leaks.
- With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
- Remove and discard the 2-exhaust Y-pipe flange nuts. Discard the gasket. To install, tighten to 40 Nm (30 lb-ft).
- Loosen the Torca® clamp nut. To install, tighten to 55 Nm (41 lb-ft).
- Separate the exhaust intermediate pipe from the muffler and tailpipe and remove the exhaust intermediate pipe.
- To install, reverse the removal procedure. Always install new gaskets and exhaust fasteners.
- Start the engine and check for exhaust leaks.