Exhaust System: Notes
WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
The exhaust system will vary between engine, transmission and vehicle models.
WARNING:
The normal operating temperature of the exhaust system is very high. Never attempt to repair or install any new 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.
CAUTION:
Do not use oil or grease-based lubricants on the isolators. They may cause deterioration of the rubber.
CAUTION:
Oil or greased-based lubricants on the isolators may cause the exhaust hanger isolator to separate from the exhaust hanger bracket during vehicle 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.
Use caution when removing a catalytic converter, support the catalytic converter near the rear outlet. Make sure not to damage the manifold output flare, the converter inlet flare or the studs.
During installation, clean the mating surfaces of the manifold outlet flare and the catalytic converter inlet flare, as well as the mating surfaces of the catalytic converter and the inlet pipe. Support the catalytic converter near the rear outlet. Make sure not to damage the manifold outlet flare, the converter inlet flare or the studs. To correctly seat the converter, alternately tighten the exhaust manifold-to-catalytic converter nuts to specification.
Apply anti-seize lubricant to the threads of the heated oxygen sensors (HO2S) before installation.
The exhaust system consists of the parts shown in the following illustrations and tables.