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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