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Lincoln Corsair: Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4 / Diagnosis and Testing - Exhaust System

Lincoln Corsair 2020-2024 Service Manual / Powertrain / Exhaust System / Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4 / Diagnosis and Testing - Exhaust System

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action
Fit/Finish/Body > Paint/Finish > Exhaust > Corrosion/Rust GO to Pinpoint Test C
Start/Run/Move > Noise > Exhaust > Always GO to Pinpoint Test D
Driving Performance > Lack/Loss of Power > Acceleration > Always GO to Pinpoint Test A
Safe & Secure > Smoke/Odor > Exhaust > Hot GO to Pinpoint Test B

Symptom Chart(s)

Symptom Chart - Exhaust System

NOTE: Aftertreatment components consist of some or all of the following components: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts, Exhaust Gas Heat Exchanger.

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Symptom Chart


Condition Actions
Lack of power - vehicle performance complaint   GO to Pinpoint Test A
Odour from vehicle - possible sign of smoke   GO to Pinpoint Test B
Surface rust or degradation of surface treatment   GO to Pinpoint Test C
Noise such as buzzing, drumming, thumping, ringing or hissing coming from exhaust system   GO to Pinpoint Test D

Pinpoint Tests


PINPOINT TEST A: LACK OF POWER

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - System Operation and Component Description (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Exhaust pipe pinched or crushed
  • Damaged aftertreatment components
  • Loose obstruction in exhaust
  • Restricted exhaust (possible frozen condensate in mufflers or exhaust actuator valves)

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
A1 CHECK THE EXHAUST SYSTEM FOR SIGNS OF DAMAGE
  • Inspect the exhausts system aftertreatment components and associated sensors for damage.

Is damage to the aftertreatment components and associated sensors found?
Yes INSTALL new components as necessary.
No GO to A2

A2 CHECK THE EXHAUST SYSTEM FOR OBSTRUCTIONS OR RESTRICTED FLOW
  • Inspect the exhausts system pipework for pinched or crushed components.

Is any flow restricting damage to the exhaust components seen?
Yes INSTALL new components as necessary.
No The condition may be intermittent. Advise the customer no repair is required.

PINPOINT TEST B: ODOUR FROM VEHICLE

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - System Operation and Component Description (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Damaged or contaminated aftertreatment components
  • Incorrect fuel or fuel with excessive sulfur content in fuel
  • Rich fuel conditions
  • Misfire conditions

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
B1 CHECK FOR DAMAGED AFTERTREATMENT COMPONENTS ASSOCIATED SENSORS
  • Inspect the aftertreatment components and associated components for damage.

Have the aftertreatment components or associated electronic sensors incurred damage?
Yes INSTALL a new aftertreatment components as necessary.
No GO to B2

B2 CHECK FOR INCORRECT FUEL OR FUEL WITH A HIGH SULFUR CONTENT
  • Check the residual fuel in the fuel tank for incorrect fuel or fuel that contains a high sulfur content.

Does the fuel tank contain incorrect fuel or fuel high in sulfur content?
Yes Drain the fuel tank and flush the fuel system. Refill the fuel system with fuel containing the correct level of sulfur.
No GO to B3

B3 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Using a diagnostic scan tool, perform the PCM self-test.

Are the powertrain controls operating correctly?
Yes The condition may be intermittent. Advise the customer no repair is required.
No Correct and fix any powertrain control issues. Using a diagnostic scan tool, perform the PCM self-test. Test and confirm the issue has been resolved.

PINPOINT TEST C: SURFACE RUST OR DEGRADATION OF SURFACE TREATMENT

NOTE: Surface rust is a characteristic of materials used on exhaust systems. Exposure to heat or road salt may result in surface rust.

Normal Operation and Fault Conditions

REFER to: Exhaust System - System Operation and Component Description (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Perforated catalytic converter/exhaust system

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
C1 CHECK THE EXHAUST SYSTEM FOR PERFORATIONS, RUST OR DAMAGE
  • Visually inspect the exhaust system, paying specific attention to joints, bends, low points and check for rust, perforations or surface degradation.

Are perforations, rust or damage present?
Yes INSTALL new components as necessary.
No GO to C2

C2 CHECK FOR CORRECT PCM (POWERTRAIN CONTROL MODULE) OPERATION
  • Using a diagnostic scan tool, perform the PCM self-test.

Are the powertrain controls operating correctly?
Yes The condition may be intermittent. Advise the customer no repair is required.
No Correct and fix any powertrain control issues. Using a diagnostic scan tool, perform the PCM self-test. Test and confirm the issue has been resolved.

PINPOINT TEST D: NOISE FROM EXHAUST SYSTEM

NOTE: Aftertreatment components consist of some or all of the following: Catalytic Converters, Gasoline Particulate Filters, Diesel Particulate Filters, Selective Catalytic Reduction Catalysts.

Normal Operation and Fault Conditions

REFER to: Exhaust System - System Operation and Component Description (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Description and Operation).

Possible Sources

  • Loose or damaged heat shield(s)
  • Loose or damaged exhaust isolators(s)
  • Damaged exhaust isolator hanger bracket
  • Loose or damaged aftertreatment components or mufflers
  • Exhaust system leak
  • Catalytic converter/exhaust system
  • Exhaust system grounded to chassis
  • Damaged or worn exhaust system
  • Misaligned exhaust system
  • Strain on the exhaust system

Visual Inspection and Pre-checks

  • Inspect for loose, damaged, contaminated or incorrect components.
D1 CHECK THE EXHAUST SYSTEM FASTENERS
  • Check and confirm that all exhaust system fasteners on joining connections, hanger brackets and isolators are tightened to specification.

Was exhaust noise still present after confirming all exhaust system fasteners are tightened to specification?
Yes GO to D2
No The issue has been resolved.

D2 INSPECT THE EXHAUST ISOLATORS AND HANGER BRACKETS
  • Visually inspect the condition and alignment of all exhaust system isolators and hanger brackets.

Were exhaust system isolators and hanger brackets found to be in correct alginment and in good condition?
Yes GO to D3
No INSTALL new components as necessary.

D3 CHECK FOR MISSING OR DAMAGED EXHAUST HEAT SHIELDS
  • Check for noise originating from missing or damaged exhaust heat shields.

Were the exhaust heat shields found to be present and in correct alignment?
Yes GO to D4
No INSTALL new components as necessary.

D4 CHECK THE EXHAUST SYSTEM FOR ALIGNMENT
  • Manually move the exhaust system to simulate the bouncing action of the vehicle, checking for exhaust-to-body contact whilst the exhaust system is moving.

Was the exhaust noise seen to originate from contact between the exhaust system and the surrounding components/vehicle body?
Yes Ensure the exhaust system is installed correctly 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 hammer or rubber mallet, lightly tap the resonators, mufflers, aftertreatment components and exhaust pipework, listening for loose internal baffling or internal damage.

Was noise such as rattling, clanging or twanging heard within the exhaust components?
Yes The exhaust component likely has 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 components and pipework for leaks.

Were leaks found?
Yes INSTALL new components as necessary.
No GO to D7

D7 CHECK FOR COOL DOWN PINGING
  • Run the engine and bring the exhaust system to operating temperature.
  • KOEO
  • While allowing the engine to cool, listen the exhaust system during coold down to attempt to isolate the noise complaint.

Was the exhaust complaint found to be cool down pinging?
Yes Cool down pinging is a result of the exhaust system expanding and contracting during heating and cooling. This is a normal condition. The issue has been resolved.
No The condition may be intermittent. Advise the customer no repair is required.


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