Ford Falcon. Manual - part 287
309-00-6 Exhaust
System 309-00-6
REMOVAL AND INSTALLATION
All Rear Muffler Assemblies
6 Cylinder Catalyst Assembly
Removal and Installation
Removal and Installation
1. Remove nuts connecting catalyst assembly to
WARNING: Care must be taken so as to avoid
manifold.
damage to exhaust system & fuel tank heat
NOTE: Manifold studs and mating exhaust nuts
shields. If shields are damaged or substantially
are one time use parts only and must be
distorted they should be replaced, and the fuel
replaced.
tank inspected for damage.
2. Remove bolts connecting intermediate muffler to
1. Remove the nuts connecting the intermediate
catalyst assembly. Discard the gasket.
muffler assembly to the rear muffler assembly.
Discard the gasket.
NOTE: The bolts connecting the intermediate
muffler to the catalyst assembly are of a
2. Disconnect rear muffler assembly from the
self-threading type that have been used to tap
hangers at the front and rear of the muffler and
thread directly into the catalyst assembly outlet
remove by pushing muffler rearward and gently
pipe flange. Conventional class 10.0 bolts with
moving ’over-axle pipe’ through cavity above IRS
similar geometry can be used in place of these
(sedan only).
self-threading bolts.
3. Installation is the reverse of the removal
procedure.
3. Disconnect the catalyst assembly from the hanger
on the outlet pipe and remove.
NOTE: Install new gaskets at each point.
4. Installation is the reverse of the removal
NOTE: Assembly is the reverse of the removal
procedure.
procedure. To ease reattachment of rubber
NOTE: Care must be taken when attaching a
isolators to hanger brackets, a mild detergent
catalyst assembly to a manifold such that it is
solution can be applied to the bracket.
correctly aligned. To achieve this, firstly do up the
NOTE: Care must be taken when attaching a
nuts by hand as far as possible (using a socket
catalyst assembly to a manifold such that it is
with extension), and then torque the nuts up in
correctly aligned. To achieve this, firstly do up the
steps alternating between the two until the
nuts by hand as far as possible (using a socket
nominal torque is achieved.
with extension), and then torque the nuts up in
steps alternating between the two until the
8 Cylinder Catalyst Assemblies (LHS &
nominal torque is achieved.
RHS)
NOTE: Upon conclusion of assembly, system
should be checked for leaks and correct
Removal and Installation
alignment, refer Sections on Diagnosis and
1. Remove nuts connecting catalyst assembly to
Testing and General Procedures.
manifold. Both sides will require the removal of an
additional nut retaining a heat shield.
All Intermediate Muffler Assemblies
NOTE: Manifold studs and mating exhaust nuts
are one time use parts only and must be
Removal and Installation
replaced.
1. Remove bolts connecting intermediate muffler to
catalyst assembly (6 cylinder) or Y-pipe assembly 2. Remove nuts connecting Y-pipe to catalyst
(8 cylinder). Discard the gasket.
assembly. Discard the gasket(s).
NOTE: The bolts connecting the intermediate
3. Disconnect catalyst assembly from the hanger on
muffler to the catalyst/Y-pipe assemblies are of a
the outlet pipe and remove.
self-threading type that have been used to tap
4. Installation is the reverse of the removal
thread directly into the catalyst assembly outlet
procedure.
pipe flange (6 cylinder) or directly into weld nuts
NOTE: Care must be taken when attaching a
on the Y-pipe outlet flange (8 cylinder).
catalyst assembly to a manifold such that it is
Conventional class 10.0 bolts with similar
correctly aligned. To achieve this, firstly do up the
geometry can be used in place of these
nuts by hand as far as possible (using a socket
self-threading bolts.
with extension), and then torque the nuts up in
2. Remove the nuts connecting the intermediate
steps alternating between the two until the
muffler assembly to the rear muffler assembly.
nominal torque is achieved.
Discard the gasket.
3. Disconnect intermediate muffler assembly from
the hanger on the outlet pipe and remove.
4. Installation is the reverse of the removal
procedure.
G56318 en