SECTION 309-00: Exhaust System
2003 Focus Workshop Manual
DESCRIPTION AND OPERATION
Procedure revision date: 01/24/2003
Exhaust System
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Vehicles with 2.0L Zetec-E engine
Item
Part Number
Description
1
-
Bracket
2
-
Gasket
3
-
Catalytic converter
4
-
Bracket
5
-
Gasket
6
-
Front muffler
7
-
Rear muffler
8
-
Hanger
9
-
Flexible pipe
Vehicles with 2.0L SPI engine
Item
Part Number
Description
1
-
Gasket
2
-
Catalytic converter
3
-
Bracket
4
-
Gasket
5
-
Front muffler
6
-
Rear muffler
7
-
Hanger
8
-
Bracket
9
-
Flexible pipe
Vehicles with 2.3L PZEV Engine
Item
Part Number
Description
1
5G232
Catalytic converter
2
5K222
Mounting bracket
3
5K282
Head shield
4
9451
Gasket
5
5A262
Insulator
6
5E292
Converter and muffler assembly
7
9448
Gasket
8
5G203
Flex Pipe
NOTE: The exhaust systems shown in this section are production systems.
The exhaust systems are of a two-piece construction for production and five-piece construction for service.
Catalytic Converter
The catalytic converter fitted to the Focus range resembles a small muffler. Because of the high temperatures at which the catalytic converter operates, the vehicle body areas around the catalytic converter are protected by heat shields. The catalytic converter controls three emissions; Hydro carbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx).
Catalyst deactivation due to poisoning
Sulphur (S) in the fuel can cause deactivation of the catalyst.
Lead (Pb) in fuel can cause a severe deactivation at levels above 5 mg per liter of fuel. It is therefore essential that vehicles with catalytic converters always operate on unleaded fuel.
Zinc (Zn) and phosphorus (P) present in some oils, can cause deactivation if oil consumption is high.
The effect of sulphur is felt most if it is released from the catalytic converter as hydrogen sulphide (H2S). This has an unpleasant odor similar to rotten eggs. Changing the fuel manufacturer may help in reducing this phenomena.
To minimize H2S emissions, it is essential that the idle CO level is within specification and that the engine emission system is functioning correctly. For additional information, refer to
Section 303-08A or
Section 303-08B.
CAUTION: If temperatures exceeding 900°C are achieved the catalyst substrates will start to deteriorate. It is important that the cause is defined and rectified if subsequent melts are to be prevented.
Catalyst melts are normally accompanied by loss of power due to excessive back pressure. For additional information, refer to
Section 303-07A or
Section 303-07B.
High substrate temperatures are caused by the ignition or the fuel systems. For additional information, refer to
Section 303-07A or
Section 303-07B.
Misfires at high engine speed may result in an almost instantaneous melt.
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