Exhaust System - Sulfur Smell/Rotten Egg Odor
Article No.94-22-7
10/31/94
EXHAUST SYSTEM - OBJECTIONABLE ODOR - SULFUR SMELL - 3.8L - REPLACEMENT CONVERTER - VEHICLES BUILT PRIOR TO 4/1/94
FORD:
1993-94 TAURUS
LINCOLN-MERCURY:
1993-94 SABLE
ISSUE:
An objectionable exhaust, sulfur or rotten egg smell may be noticed during various driving conditions. This is caused by the lack of a sufficient Nickel Oxide washcoat on the catalytic converter substrate which allows too much H2S (Sulfur smell) to be released during certain driving conditions.
ACTION:
The smell may be significantly diminished by installing a current production level catalyst. Use the following service procedure to determine if a "double nickel" catalyst with a double coating of nickel oxide on the substrate may be installed. The catalyst is most effective in geographic areas with high levels of sulfur in the fuel. Refer to the following service procedures for details.
DIAGNOSIS PROCEDURE
1. Road test vehicle to verify concern.
2. Perform the diagnostic procedure in the 1993-94 Powertrain Control/Emissions Diagnosis Service Manual. Service as required.
3. Check all hoses and related connections for the Evaporative Emission (EVAP) system. Refer to the 1993-94 Powertrain Control/Emissions Diagnosis Service Manual, Section 11A. Service as required.
4. 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.
5. Verify the fuel pressure and perform the injector leak-down test. Service as required.
6. If sulfur smell still exists after performing all of the above steps, install a new exhaust assembly with a revised catalytic converter (F4DZ-5F250-H).
FRONT EXHAUST PIPE ASSEMBLY REMOVAL
1. Disconnect the two (2) Heated Exhaust Gas (HO2S) sensors from the vehicle harness.
NOTE:
IF POSSIBLE, REMOVE THE TWO (2) H02S SENSORS BEFORE REMOVING THE EXHAUST PIPE ASSEMBLY FROM THE VEHICLE. USE THE H02S INSTALLATION TOOL OTC T79P-9472A, OR EQUIVALENT. SAVE THE SENSORS FOR REINSTALLATION. IF NO TOOL IS AVAILABLE, THEN REMOVE THE H02S SENSORS AFTER THE EXHAUST PIPE ASSEMBLY HAS BEEN 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.
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. Discard the flex joint gasket.
5. Remove the front exhaust pipe assembly from the vehicle.
FRONT EXHAUST PIPE ASSEMBLY INSTALLATION
1. Reinstall the two (2) H02S sensors. Apply a light coat of Loctite Nickel Anti-Seize, PN 23508, to the threads of the sensors. Refer to the end of this service bulletin for ordering information.
NOTE:
IF THE H02S INSTALLATION TOOL IS NOT AVAILABLE, INSTALL THE H02S SENSORS BEFORE INSTALLING THE EXHAUST PIPE ASSEMBLY. IF THE TOOL IS AVAILABLE, INSTALL THE H02S SENSORS AFTER THE NEW EXHAUST PIPE ASSEMBLY IS INSTALLED IN THE VEHICLE. AGAIN, CAUTION SHOULD BE TAKEN NOT TO DAMAGE THE H02S SENSORS.
2. Install the new front exhaust pipe assembly (F4DZ-5F250-H) using the old manifold stud bolts and nuts if possible.
3. Tighten the exhaust manifold attaching nuts (N620482-S2) to 34-48 N-m (25-35 lb.ft.).
4. Install the bolt and nut retainer (N606705-S2) and nut (N802068-S2) to the transaxle housing. Tighten to 30-40 N-m (22-30 lb.ft.) and 34-46 N-m (25-35 lb.ft.). Use the old bolt, nut retainer and nut if possible.
5. Install a new flat gasket (FOOY-5E241-A) and attach the exhaust assembly to the flex pipe flange.
6. Install the flex pipe flange bolts (N806777-S2) and nuts (N802641-S2). Tighten to 34-46 N-m (25-35 lb.ft.).
7. Reconnect the electrical connectors to the H02S sensors (install the H02S sensors if not done so previously).
8. Check for exhaust leaks.
NOTE:
THE REPLACEMENT CATALYSTS ARE HIGHLY ACTIVE AND MAY INITIALLY GENERATE THE SAME OR HIGHER LEVELS OF SULFUR (H2S) SMELL AFTER INSTALLATION. CATALYST BREAK-IN TIME IS APPROXIMATELY 2,000 MILES (3200 KM). BREAK-IN TIME CAN VARY BASED ON DRIVING HABITS, TYPE OF FUEL USED, AND CLIMATIC CONDITIONS (BE SURE CUSTOMER IS ADVISED).
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.
The part number your Ford Dealership should use when ordering the Loctite Nickle Anti-Seize direct from Loctite's Cleveland, OH office is 23508.
The Ford Dealership should call 1-800-338-9000, 8 AM - 5 PM (EST), or FAX 1-800-548-7389 and ask for the Ford Anti-Seize Program, PN 23508.
The Dealer should have a purchase order (or name of Dealer) as well as a Ship To address. The charges are:
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
942207A Replace Catalytic Converter 1.4 Hrs.
DEALER CODING
BASIC PART NO. CONDITION CODE
5F250 49
OASIS CODES: 403000