Ford Falcon. Manual — part 286
309-00-2 Exhaust
System 309-00-2
SPECIFICATIONS
6 Cylinder Torque Specifications
Description
Nm
Catalyst assembly inlet pipe to
25 Nm
manifold nuts.
Catalyst assembly outlet pipe to
35 Nm
intermediate muffler assembly inlet
pipe bolts.
Intermediate muffler outlet pipe to rear
35 Nm
muffler inlet pipe nuts.
8 Cylinder Torque Specifications
Description
Nm
Catalyst assembly inlet pipes to
25 Nm
manifold nuts (LHS & RHS).
Catalyst assembly outlet pipes to
35 Nm
Y-pipe assembly inlet pipe nuts.
Y-pipe assembly outlet pipe to
35 Nm
intermediate muffler assembly inlet
pipe bolts.
Intermediate muffler outlet pipe to rear
35 Nm
muffler inlet pipe nuts.
HEGO sensor to catalyst assembly
47.5 Nm
inlet pipe (LHS only).
XR8 Y-pipe band clamp
17 (22Max)
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309-00-3 Exhaust
System 309-00-3
DESCRIPTION AND OPERATION
The TWC is designed to provide a long life. No
Exhaust System
maintenance is necessary for the TWC. Avoid the
following conditions:
The exhaust system provides an exit for exhaust
gases and reduces engine noise by passing exhaust
Driving with a misfiring engine
gases through the three way catalytic converter
Continuously running the engine with a misfiring
(TWC), an intermediate muffler forward of the rear
spark plug.
axle and a rear muffler. Rubber exhaust hanger
Parking or stopping the vehicle over combustible
insulators attach the exhaust system to the hanger
material such as dry grass. The material can be
brackets.
ignited by the high temperatures of the TWC and
the muffler.
CAUTION: Under no circumstances should
non "Original Equipment" exhausts be fitted.
Heat Shields
Exhaust system heat shields attached to the
Three Way Catalytic Converter (TWC)
underbody protect the vehicle from exhaust system
The three way catalytic converter (TWC) plays a
heat and should be inspected at regular intervals to
major role in the emission control system. The TWC
ensure they are not dented or out of position. If a
operates as a gas reactor. Its catalytic function is to
shield is damaged or shows evidence of deterioration,
speed the heat-producing chemical reaction of
it should be replaced. The shields for the intermediate
components in the exhaust gases in order to reduce
muffler, over-axle pipe, and rear muffler are installed
air pollutants.
separately.
Precautions
WARNING: The normal operating temperature
of the exhaust system is very high. Never work
around or attempt to repair any part of the
exhaust system until it has cooled. Use special
care when working around the TWC. The TWC
heats to a high temperature after only a short
period of engine operation. Failure to follow these
instructions may result in personal injury.
WARNING: Exhaust gases contain carbon
monoxide which can be harmful to health and are
potentially lethal. Exhaust system leaks should be
repaired immediately. Never operate the engine in
enclosed areas. Failure to follow these
instructions may result in personal injury.
CAUTION: Do not use leaded fuel in a vehicle
equipped with a TWC.
CAUTION: In a vehicle that is continually
misfueled, the lead in the fuel will be deposited in
the TWC and completely blanket the catalyst.
Lead reacts with platinum to ’’poison’’ the
catalyst. Continuous use of leaded fuel can
destroy the catalyst and render the TWC useless.
CAUTION: The addition of lead to the TWC
can 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
base to sinter or burn, destroying the TWC.
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309-00-4 Exhaust
System 309-00-4
DIAGNOSIS AND TESTING
Exhaust System
This section covers general exhaust system
diagnosis, tests, adjustment and repair procedures.
For exhaust system component removal,
disassembly, assembly, installation, clearances,
torque requirements, and bracket locations refer to
the illustrations in Removal and installation section.
Inspection and Verification
Inspect the inlet pipe, outlet pipe, and muffler for
cracked joints, broken welds and corrosion damage
(holes) that would result in a leaking exhaust system.
Inspect the clamps, brackets and insulators for cracks
and stripped or badly corroded bolt threads.
Pinpoint Tests
Engine performance
An exhaust system performance complaint, such as
excessive back pressure is usually noticeable by its
effect on engine performance. For diagnosis of
exhaust system problems that affect engine
performances, refer to section Section 303-00,
Section 303-01A, Section 303-01B, Section
303-01C(engine diagnosis and testing).
Leaks
External leaks in the exhaust system are often
accompanied by noises or exhaust gas emitted from
under the vehicle. A visual inspection of the exhaust
system usually will show the location of the leak. Look
for holes, ruptured joints and corroded areas in the
muffler, inlet pipe and outlet pipe. Examine joints and
connections for deposits that would be caused by
exhaust gas leakage.
Noise/Vibration
A misaligned exhaust system is usually indicated by
vibration, grounding, rattling, or binding of the
components. Often the associated noise is hard to
distinguish from other chassis noises. Use a rubber
mallet to lightly tap on exhaust components and heat
shields to identify noise and vibration areas. It is
important that exhaust clearances and setting
procedures as shown in illustrations in Removal and
installation section be adhered to whenever repairs
involving the exhaust system are carried out. Inspect
exhaust system welds, insulators and insulator
brackets for cracks or breaks. Shake the exhaust
system to identify any exhaust-to-body/chassis
contact. Ensure that the insulators are in a neutral
position when the exhaust system is hot, before
replacing components in an endeavor to correct a
noise, vibration or harshness problem.
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309-00-5 Exhaust
System 309-00-5
GENERAL PROCEDURES
Exhaust System Alignment
NOTE: The exhaust system must be free of leaks,
binds, grounding and excessive vibration.
Exhaust system vibration, grounding or binds are
usually caused by: loose, broken insulators or
brackets or improperly connected pipes. Any of the
aforementioned conditions may cause changes to
clearances of the exhaust system components. If any
of these conditions exist, the exhaust system
components must be checked, adjusted or replaced to
make certain the specified clearances (refer to the
illustrations in Removal and installation section) are
maintained.
Perform the following procedures to adjust the
exhaust system components:
1. Loosen the securing hardware, and the pipe
support brackets.
2. Progressively align the exhaust system, using the
relative lateral position of the hanger brackets
(exhaust/body mounted) and rubber isolators as a
guide.
NOTE: Exhaust hangers are designed to be
under a small amount of tension when the
exhaust system is cold. This allows for thermal
expansion of the system during normal operation.
3. Tighten all attachments.
NOTE: Tighten the exhaust manifold nuts evenly
and alternately.
4. Start the engine and check the exhaust system for
leaks.
NOTE: Mufflers, inlet pipes and outlet pipes,
gaskets, brackets, and insulators should be
replaced if they are defective or become badly
corroded. Do not attempt to repair these parts.
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