Engine/Exhaust - Cold Start Knocking Noise

Article No.
04-2-1

02/09/04

^ ENGINE - EXHAUST - KNOCK DURING INITIAL COLD START

^ NOISE - KNOCK DURING INITIAL COLD START

FORD:
2003-2004 CROWN VICTORIA

LINCOLN:
2003-2004 TOWN CAR

MERCURY:
2003-2004 GRAND MARQUIS

ISSUE

Some vehicles may exhibit an engine knock during initial cold start, the knock will cease after the engine is fully warmed up.

ACTION

To service, install Exhaust Shield kit (3W7Z-5E258-AA). Refer to the following Service Procedure.

SERVICE PROCEDURE

NOTE
DO NOT REMOVE EXISTING CATALYTIC CONVERTER SHIELDS.

1. Place vehicle on a lift.

NOTE
ALLOW VEHICLE EXHAUST SYSTEM TO COOL DOWN BEFORE PROCEEDING TO STEP 2.





2. Place top half of the shield on the catalytic converter. To properly identify the top and bottom halves of the shields refer to (Figure 1).





3. Position bottom half of shield in place. For ease of installation hold the bottom shield in place with a screw type stand (Figure 2).





4. Using the supplied clamps secure the shields in place. Index the clamps opposite to each other so they compress the shields evenly. Place the clamps beside the existing seams of the catalytic converter, refer to (Figure 3) for more detail.

5. Tighten the clamps evenly. Torque to 5-10 N.m (44-88 lb-in).

6. Once installation is completed visually inspect the metal corners of the shield to make sure they are not contacting the catalytic converter. Metal to metal contact may transmit noise.

7. Remove screw type stand.

8. Cut excess material from clamps.

9. Repeat steps 1-8 for second catalytic converter.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

OPERATION DESCRIPTION TIME

040201A Install Exhaust Shield kit: 0.5 Hr.
Includes Time For Both
Catalytic Converters

DEALER CODING
CONDITION
BASIC PART NO. CODE
5E212 42





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