The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures. REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).
Symptom
Action
Body and Paint > Paint/Finish > Exhaust > Corrosion/Rust
GO to Pinpoint Test C
Operation/Drive/Move > Noise > Exhaust > Always
GO to Pinpoint Test D
Drivability > Lack/Loss of Power > Acceleration > Always
GO to Pinpoint Test A
Safe and Secure > Smoke/Odor > Exhaust > Hot
GO to Pinpoint Test B
Symptom Chart
Symptom Chart - Exhaust System
The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures. REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).
Symptom Chart
Condition
Action
Lack of Power - Vehicle Concern
GO to Pinpoint Test A
Vehicle odor - possible sign of smoke
GO to Pinpoint Test B
Surface rust or surface finish degradation
GO to Pinpoint Test C
Noise such as buzzing, drumming, knocking, rattling or hissing coming from the exhaust system
GO to Pinpoint Test D
Pinpoint Tests
DIAGNOSTIC TEST A: LACK OF POWER
Normal Operation and Fault Symptoms
REFER TO: Exhaust System - System Operation and Component Description (309-00C Exhaust System, Description and Operation).
Possible Sources
Exhaust pipe pinched or crushed
Damaged aftertreatment system components
Loose obstruction in the exhaust
Restricted exhaust (possible frozen condensation in mufflers or driveline exhaust valves)
Visual Inspection and Pre-checks
Check for loose, damaged, contaminated or incorrect components.
A1 CHECK THE EXHAUST SYSTEM FOR DAMAGE
Inspect the aftertreatment system components and associated sensors for damage.
Is damage present on the aftertreatment system components or associated sensors?
Yes
INSTALL new components as necessary.
No
GO to A2
A2 CHECK THE EXHAUST SYSTEM FOR OBSTRUCTIONS OR FLOW RESTRICTION
Inspect the exhaust piping for pinched or crushed components.
Is any damage visible to exhaust system components that restricts flow?
Yes
INSTALL new components as necessary.
No
The condition may be intermittent. Inform the customer that no repair is required.
DIAGNOSTIC TEST B: VEHICLE ODOR
Normal Operation and Fault Symptoms
REFER TO: Exhaust System - System Operation and Component Description (309-00C Exhaust System, Description and Operation).
Possible Sources
Damaged or contaminated aftertreatment system components
Incorrect fuel or fuel with high sulfur content
Rich fuel conditions
Misfire conditions
Visual Inspection and Pre-checks
Check for loose, damaged, contaminated or incorrect components.
B1 CHECK AFTERTREATMENT COMPONENTS AND ASSOCIATED SENSORS FOR DAMAGE
Inspect the aftertreatment system components and associated components for damage.
Are the aftertreatment system components or associated electronic sensors damaged?
Yes
INSTALL new aftertreatment system components as necessary.
No
GO to B2
B2 CHECK FOR INCORRECT FUEL OR FUEL WITH HIGH SULFUR CONTENT
Check the fuel remaining in the fuel tank for incorrect fuel or fuel with high sulfur content.
Is incorrect fuel or fuel with high sulfur content present in the fuel tank?
Yes
Drain the fuel tank and flush the fuel system. Refill the fuel system with fuel containing the correct sulfur level.
No
GO to B3
B3 CHECK PCM (POWERTRAIN CONTROL MODULE) OPERATION
Using the diagnostic scan tool, perform a PCM self-test.
Are the powertrain controls operating correctly?
Yes
The condition may be intermittent. Inform the customer that no repair is required.
No
Correct and resolve any powertrain control concerns. Using a diagnostic scan tool, perform a PCM self-test. Test and confirm the concern is resolved.
DIAGNOSTIC TEST C: SURFACE RUST OR SURFACE FINISH DEGRADATION
Normal Operation and Fault Symptoms
REFER TO: Exhaust System - System Operation and Component Description (309-00C Exhaust System, Description and Operation).
Possible Sources
Perforated catalytic converter/exhaust system
Visual Inspection and Pre-checks
Check for loose, damaged, contaminated or incorrect components.
C1 CHECK THE EXHAUST SYSTEM FOR HOLES, RUST OR DAMAGE
Visually inspect the exhaust system, paying particular attention to joints, bends, low points, and check for rust, perforation or surface degradation.
Are there any perforations, rust or damage?
Yes
INSTALL new components as necessary.
No
GO to C2
C2 CHECK PCM (POWERTRAIN CONTROL MODULE) OPERATION
Using the diagnostic scan tool, perform a PCM self-test.
Are the powertrain controls operating correctly?
Yes
The condition may be intermittent. Inform the customer that no repair is required.
No
Correct and resolve any powertrain control concerns. Using a diagnostic scan tool, perform a PCM self-test. Test and confirm the concern is resolved.
DIAGNOSTIC TEST D: EXHAUST SYSTEM NOISE
Normal Operation and Fault Symptoms
REFER TO: Exhaust System - System Operation and Component Description (309-00C Exhaust System, Description and Operation).
Possible Sources
Loose or damaged heat shield(s)
Loose or damaged exhaust isolators
Damaged exhaust isolator hanger bracket
Loose or damaged aftertreatment system components or mufflers
Exhaust system leak
Catalytic converter/exhaust system
Exhaust system grounded to chassis
Damaged or worn exhaust system
Incorrect exhaust system
Exhaust system loading
Visual Inspection and Pre-checks
Check for loose, damaged, contaminated or incorrect components.
D1 CHECK THE EXHAUST SYSTEM MOUNTINGS
Check and confirm that all exhaust system fasteners at connections, hanger brackets and isolators are tightened to specification.
Did the exhaust noise persist after confirming all exhaust system mountings are tightened to specification?
Yes
GO to D2
No
The concern is resolved.
D2 CHECK THE EXHAUST ISOLATORS AND HANGER BRACKETS
Visually check the condition and alignment of all exhaust isolators and hanger brackets.
Are the exhaust isolators and hanger brackets correctly aligned and in good condition?
Yes
GO to D3
No
INSTALL new components as necessary.
D3 CHECK FOR MISSING OR DAMAGED HEAT SHIELDS
Check for noise caused by missing or damaged exhaust heat shields.
Are the exhaust heat shields present and in the correct position?
Yes
GO to D4
No
INSTALL new components as necessary.
D4 CHECK THE EXHAUST SYSTEM FOR ALIGNMENT
Manually move the exhaust system to simulate vehicle bouncing, check for exhaust contact with the body while moving the exhaust system.
Was the exhaust noise found to be caused by contact between the exhaust system and surrounding components/vehicle body?
Yes
Make sure the exhaust system is correctly installed on the exhaust hangers and isolators. INSTALL new components as necessary.
No
GO to D5
D5 CHECK THE EXHAUST SYSTEM FOR INTERNAL DAMAGE
Using a soft-faced hammer or a rubber mallet, lightly tap the resonators, mufflers, aftertreatment system components and exhaust pipes while listening for loose internal baffles or internal damage.
Were any rattling, clunking or buzzing noises heard from the exhaust system components?
Yes
The exhaust component is likely to have internal damage. INSTALL new components as necessary.
No
GO to D6
D6 CHECK THE EXHAUST SYSTEM FOR LEAKS
With the engine running, visually inspect the exhaust system components and pipes for leaks.
Were any leaks found?
Yes
INSTALL new components as necessary.
No
GO to D7
D7 CHECK FOR EXHAUST HEAT TICK
Start the engine and bring the exhaust system to operating temperature.
KOEO
Allow the engine to cool, listen to the exhaust system during cool-down to isolate the noise complaint.
Was the exhaust system complaint related to heat tick?
Yes
Cooling ticks in the exhaust system are caused by expansion and contraction during heating and cooling. This is a normal condition. The concern is resolved.
No
The condition may be intermittent. Inform the customer that no repair is required.
?
Test yourself
A quick Ford Escape quiz: every answer comes with an explanation and a link to the manual page.
.jpg){kind=icon}
DIAGNOSTIC TEST A: LACK OF POWER