Exhaust Sulfur Smell
Article No.92-16-4
07/29/92
EXHAUST - 3.8L - SULFUR SMELL - VEHICLES BUILT AFTER 11/20/89
LINCOLN-MERCURY:
1990-91 CONTINENTAL
CALIBRATION:
0-16D-R05, 1-16D-R00, 1-16D-R10
WARNING:
THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE. PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS.
ISSUE:
An objectionable exhaust sulfur smell (rotten egg odor) may be experienced during various driving conditions. This may be caused by the calibration of the front exhaust converter and pipe assembly.
ACTION:
Perform the required diagnostics and, if necessary, install a revised design catalytic converter.
1. Perform the diagnostic procedures in the 1990-91 Engine/Emissions Diagnosis Shop Manual. Service as required.
2. Check all hoses and related connections for the Evaporative Emission (EVAP) system. Refer to the 1990-91 Engine/Emissions Diagnosis Shop Manual, Section 7 (1990 application) and Section 12 (1991 application). Service as required.
3. Check the hose connection at the base of the Pressure Feedback EGR (PFE) sensor and reconnect if not connected. Use a mirror to inspect the underside of the PFE sensor for damage or burns. Replace the PFE sensor if it is damaged or burned.
4. Verify the fuel pressure and perform the injector leak-down test. Service as required.
5. If the sulfur smell still exists after performing all of the above steps, install a new exhaust assembly with a revised catalytic converter (F2DZ-5F250-C).
FRONT EXHAUST PIPE ASSEMBLY - REMOVAL
1. Disconnect the two (2) Heated Exhaust Gas Oxygen (HEGO) sensors from the vehicle, Figure 1.
NOTE:
IF POSSIBLE, REMOVE THE TWO (2) HEGO SENSORS BEFORE REMOVING THE EXHAUST PIPE ASSEMBLY FROM THE VEHICLE. USE THE HEGO INSTALLATION TOOL OTC T79P-9472A OR EQUIVALENT. SAVE THE SENSORS FOR REINSTALLATION. IF NO TOOL IS AVAILABLE, THEN REMOVE THE HEGO SENSORS AFTER THE EXHAUST PIPE ASSEMBLY HAS 13EEN REMOVED FROM THE VEHICLE.
CAUTION:
TAKE CARE NOT TO DAMAGE THE SENSORS.
2. Remove the front and rear exhaust pipe assembly flange nuts from the exhaust manifolds. Save the manifold stud bolts and nuts if possible.
3. Remove the bolt and nut retainers at the transmission case.
4. Remove the two (2) retaining nuts and bolts from the exhaust pipe assembly outlet connection. Save the nuts and bolts if possible. Discard the flex joint gasket.
5. Remove the front exhaust pipe assembly from the vehicle.
FRONT EXHAUST PIPE ASSEMBLY - INSTALLATION
1. Modify the new front exhaust pipe assembly (F2DZ-5F250-C) before installation.
a. Cut the upper bracket off as close to the weld as possible, Figure 1.
b. Use a cutting torch or a cutting wheel to perform this operation.
CAUTION:
TAKE CARE NOT TO DAMAGE THE LOWER BRACKET.
2. Reinstall the two (2) HEGO sensors.
NOTE:
IF THE HEGO INSTALLATION TOOL IS NOT AVAILABLE, INSTALL THE HEGO SENSORS BEFORE INSTALLING THE EXHAUST PIPE ASSEMBLY. IF THE TOOL IS AVAILABLE, INSTALL THE HEGO SENSORS AFTER THE NEW EXHAUST PIPE ASSEMBLY IS INSTALLED IN THE VEHICLE. AGAIN CAUTION SHOULD BE TAKEN NOT TO DAMAGE THE HEGO SENSORS.
3. Install the new front exhaust pipe assembly (F2DZ-5F250-C) using the old manifold stud bolts and nuts if possible.
4. Tighten the exhaust manifold attaching nuts (N620482-S2) to 26-34 lb.ft. (34-47 N-m).
5. Install the bolt and nut retainer (N807325-S2) to the transmission case. Tighten to 23-29 lb.ft. (30-40 N-m). Use the old bolt and nut retainer if possible.
6. Install a new flat gasket (FOOY-5E241-A) and attach the exhaust assembly to the flex-pipe flange.
7. Install the flex pipe flange bolts (56142-S100) and nuts (391188-S100). Tighten to 25-36 lb.ft. (33-50 N-m)
8. Reconnect the electrical connectors to the HEGO sensors.
9. Check for exhaust leaks.
Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
OTHER APPLICABLE ARTICLES:
NONE
WARRANTY STATUS:
Eligible Under Basic Warranty Coverage For 1990 Models, Bumper To Bumper For 1991 Models, Emissions Warranty Coverage For All Models
OPERATION DESCRIPTION TIME
921604A Perform Engine/Emission 0.5 Hr.
Diagnostic Procedure
921604B Check All Hoses and 0.6 Hr.
Related Connections
(Includes A)
921604C Check Pressure Feedback 0.7 Hr.
EGR (Includes A & B)
921604D Replace Pressure 1.2 Hr.
Feedback EGR (PFE),
Includes Time For A, B And
C
921604E Verify Fuel Pressure And 2.0 Hr.
Perform Fuel Injector
Leak-Down Test,
Includes Time For Operations
A, B, C And D
921604F Replace Front Exhaust Pipe 2.9 Hr.
Assembly, Includes Time
For Operations A, B, C, D
And E
DEALER CODING
BASIC PART NO. CONDITION CODE
5F250 49
OASIS CODES:
403000