Repair 7

Casting numbers are a unique stamp on the engine parts to tell when a part was originally designed and what car it was originally designed for. This does not mean that the part was not used on other cars. Most casting numbers are stamped into the part itself; others have the number molded on the part. Some casting numbers can be ink-stamped while others are printed on paper, which is then wrapped around the part.

Instructions

1

Identify which type of Ford Falcon engine you have by looking in the owners manual. There are two casting types for this make of engine, the 221 and the 260.

2

Look near the rear of the engine block, under the intake manifold, for the casting number on a 221 engine. 221 casting numbers are: C2OE-6069-A, B, C, D OR E

C3OE-6069-A.

3

Locate the casting number for a 260 engine under the right side cylinder bank near the rear of the engine block. 260 casting numbers are: C2OE-6069-F, C3OE-6069-B, C4OE-6069-B.

There are a number of different ways to upgrade and modify your vehicles exhaust system. By swapping out your cars muffler with a glass pack muffler, you can affect the noise level and performance abilities of your vehicle. You should consider all the possible side effects of altering your exhaust system before you put a glass pack muffler on your car or truck.

What is a Glass Pack?

Glass pack mufflers are designed to allow air to flow directly through the exhaust pipe and reduce back pressure. The exhaust channel of a glass pack muffler contains a fiberglass barrier, which helps muffle the exhaust noise. Glass pack mufflers do not contain baffles, which slow airflow through the muffler. Glass packs typically do not muffle as much sound as stock vehicle mufflers, so installing a glass pack will probably make your vehicles exhaust system louder.

Availibility and Cost

Glass pack mufflers are widely available from a variety of different manufacturers. In terms of exhaust modifications, glass packs are a relatively inexpensive modification. In most cases, you will be able to purchase the glass pack itself for less than $50.

Pros and Cons of Glass Packs

The main benefit of installing a glass pack is that you may be able to improve exhaust flow and reduce the amount of back pressure in your exhaust. Back pressure is created when the flow of exhaust through a muffler is restricted. Depending on the type of vehicle and engine, reducing back pressure can improve performance by allowing exhaust gases to flow out of the vehicle more quickly.

Legalities of a Glass Pack

The laws governing automobile exhaust modifications will vary, depending on the area in which you live. You should check your state and local laws before swapping out your cars muffler for an aftermarket glass pack muffler. States where emissions testing and inspections are done are the most likely to have laws affecting the modifications that can be done to an exhaust system. Failure to obey exhaust and emissions laws can lead to fines and even the loss of the ability to drive your vehicle on public roadways.

Although not essential, all modern gasoline automobile engines depend on exhaust gas recirculation or EGR valves to reduce toxic nitrogen oxides from emissions. The removal of EGR valves, while long debated, has not been shown to have any performance benefits.

Function

Dangerous nitrogen oxide gases form when gasoline combustion chambers reach temperatures in excess of 2500 degrees Fahrenheit. To combat this, the EGR valve was introduced in 1973 by General Motors to recirculate exhaust gases into the combustion chamber, drastically reducing temperatures and the formation of nitrogen oxides. EGR valves do not function at idle or wide open throttle and generally increase fuel economy and performance.

Disconnecting the EGR Valve

For some, the benefit of more engine bay space is enough to make removing the EGR valve worthwhile. In order to do so without interferring with engine operation, the engines electronic control module (ECM) must be set to never activate the missing EGR. Additionally, an EGR plate must be installed to cover the hole in the intake manifold where the EGR valve was installed.

Considerations

On most cars a missing EGR valve will cause the vehicle to fail emissions testing because of a tripped check engine code and the presence of heightened levels of nitrogen oxides.

Since the introduction of the Onboard Diagnostics II (OBD II) system in 1995, two oxygen sensors -- front and rear -- monitor engine performance and emissions in all American-sold vehicles. These small, but vitally important components communicate with the engine control unit to maximize performance and minimize emissions, and should be replaced or fixed immediately if found to be malfunctioning.

Front Oxygen Sensor Function

The front -- or upstream -- oxygen sensor, so named for its position in front or upstream of the catalytic converter in the exhaust manifold, measures the amount of unburned oxygen present in the exhaust that exits the engines combustion chamber by producing and reporting a voltage level to the ECM. This indicates the air to fuel ratio that the engine is receiving and whether or not the ECM needs to alter that mixture in order to reach the proper 14.7:1 ratio.

Rear Oxygen Sensor Function

The rear oxygen sensor is located downstream of the catalytic converter, and has a more basic function: it monitors the effectiveness of the catalytic converter. Tasked with removing many of the harmful toxins from engine exhaust, the catalytic converter is an important part of the exhaust process. The ECU compares data compiled from the rear oxygen sensor with that of the front oxygen sensor to ensure that the catalytic converter is doing its job. A non-functioning rear oxygen sensor wont affect performance, but it will likely trip a dashboard indicator.

Design

Although they have different purposes, front and rear oxygen sensors employ the same basic design to measure oxygen levels. Resembling spark plugs, these small devices produce a voltage between 0.2 and 0.9 volts, based on the amount of oxygen flowing past their bulb, and relay that information to the ECU. Most modern day oxygen sensors are electrically heated on start-up until they can maintain their own 600-degree operating temperature.

Invented in the post-WWII auto boom, the MacPherson strut independent front suspension system provided automakers with a low-cost, more compact suspension design. Since then, many high-end and popular cars have relied on MacPherson struts for their performance needs, especially in Europe where smaller cars have become the standard.

History

Tasked with designing a smaller, more cost-effective and lighter alternative to Chevrolets 1940s lineup of heavy body-on-frame cars, Earle MacPherson, chief design engineer of Chevys "Light Car" project, designed what would become known as the MacPherson strut, and filed for a patent in March, 1947. This revolutionary independent front suspension design became a standard on many of Fords European cars after MacPherson left Chevrolet for Ford in late 1947, but didnt make its way into domestic Ford products until the 1970s.

Design

MacPhersons simple design relied on a spring-loaded strut to provide vertical wheel travel while also serving as a link control. The steering gear attaches directly to the shock housing. Unlike the eras widely used double-wishbone independent suspension systems, which required upper and lower control arms for each wheel, MacPhersons design employed only a lower control arm -- saving weight and space in the engine compartment.

Disadvantages

While the lighter, cheaper MacPherson strut system has clear advantages, there are drawbacks as well. MacPherson struts require a lot of vertical shock tower space, can be expensive to replace and force wheels to lose camber as the car body leans -- negatively affecting performance.

Oxygen sensors have been integrated on vehicles for more than 30 years. Located in the exhaust system, they monitor fuel-to-air ratio and catalyst efficiency. While working in a hostile environment, the sensors can eventually fail and require replacement. When this occurs, a diagnostic trouble code illuminates the check engine light to warn the driver of the component failure. Ignoring the light and not replacing the sensor can lead to further problems with the engine and emissions control system.

History

Volvo was the first auto manufacturer to feature the oxygen sensor in 1976. The sensors were specifically designed to lower emissions in the state of California to help prevent high levels of pollution. Saab soon followed suit. By 1980, almost every vehicle on the road employed one in or near the exhaust manifold. Soon, another sensor was installed into the exhaust system to monitor the efficiency of the catalytic converter. All vehicles now have at least two sensors, and some can have up to four.

Function

The upstream oxygen sensor monitors the fuel-to-air ratio for the combustible engine. A perfect mixture provides a smooth-running vehicle with lower exhaust emissions. The sensor transmits the information by radio signal to the computer of the vehicle. The computer reads the signal and makes required adjustments to the fuel-to-air mix. The downstream sensor simply monitors the catalyst efficiency and again transmits the information to the computer. When the upstream sensor fails to communicate correctly, the computer is unable to make the required adjustments and a rich or lean fuel to air mixture occurs. This causes unburned fuel to contaminate the inside of the catalytic converter.

Types

The older oxygen sensors featured a single wire to plug into the wire harness and communicate to the computer. The vehicle had to get up to operating temperature before the sensor was activated to transmit the data. This caused higher emissions to be exhausted from the engine until the sensor began to function. Newer sensors now have three to four wires. An internal heater inside the sensor heats it up more quickly to activate the function of the sensor more quickly, resulting in lower emissions.

Significance

The oxygen sensor is in place to monitor the emissions from the exhaust. Without the sensor in place or with a failed sensor, the computer cannot adjust the fuel-to-air ratio properly. This causes a rich (too much fuel) or lean (too much air) mixture. It can affect the operation of the engine and allow unburned fuel to emit down the exhaust system. When the catalyst cannot convert the unburned fuel, particles will build up on the special metals inside the catalyst. Eventually, the converter will break down inside and require replacement.

Location

As mentioned, many vehicles have multiple oxygen sensors integrated into the exhaust system. The upstream sensors are located before the catalytic converter, often near or on the manifold. Vehicles with dual manifolds will have a sensor for each. The downstream sensors are located after or in the catalytic converter. Vehicles featuring more than one converter will have one sensor for each one. Bank location of the sensors will help you determine its proper location. Bank 1 is located on the same side of the engine as the No. 1 cylinder. So a diagnostic trouble code that tells you Sensor 1 Bank 1 has failed indicates the upstream sensor on the same side as the No. 1 cylinder. Sensor 2 Bank 1 is the downstream sensor on the same side.

An induction motor works on the principle that a current is created in a coil through which a magnet (magnetic field) is moved. The current is then able to drive a motor.

Problems with Torque Ripple

In applications like actuator motors for power steering in your car, torque pulsations or ripples can affect the power in the steering mechanisms or cause unwanted noise that bothers the driver. This ripple or pulsation must be dealt with in the induction actuator motor.

Causes of Torque Ripple

This torque ripple is caused as the magnetic field in the induction motor changes direction and consequently the current in the coil also reverses polarity. This problem has also been prevalent in brushless electric motors.

Research into Torque Ripple

Places like the University of Ohio are working on ways to eliminate or minimize torque ripple in induction and electric motors. Researchers feel that the torque ripple is basically a design problem and that it can be reduced or totally eliminated by creating the correct design geometry on the motor.

The fuel pump on a motor vehicle pumps the gasoline through the engine to be ignited and create power. The fuel must pass through a fuel filter to ensure that no contaminants reach the engine. The filter traps large particles of dust and debris, stopping them from affecting the engine.

Start Difficulties

The first sign of a malfunctioning fuel pump filter is difficulty starting the car. The filter will start to block the flow of gasoline into the engine. This is mainly caused by blockage or clogging, but can also occur from a break in the filter or a misinstallation. The problem will escalate over time if untreated, and what began as a difficult start that took several attempts will become a complete inability to start the engine. Once the filter hits this point of damage the only fix is to replace it.

Stalling

A significant indicator of a faulty fuel pump filter is the stalling of the engine during use. The stall will most likely occur on an upward or downward slope (depending on the placement in the car) when the fuel is being pushed through the filter rapidly. The stall happens because of an interrupted or inconstant flow of gasoline and feels much like the car does when running out of gasoline. At this point, however, the fuel pump filter may just need a quick repair or cleaning.

Acceleration

The fuel pump filters earliest indicator of problems manifests as stunted acceleration. If the car starts running sluggishly or unresponsively it will mean the fuel pump is either off alignment or in the beginning stages of a clog. There is a good chance at this point that a simple fuel injector cleaner solution may fix this problem and the vehicle will start running efficiently again.

There have been many advancements over the years in the effort to reduce automobile emissions. These include removing additives like lead from gasoline, developing engines that get better mileage and installing parts to reduce emissions. One such part is the PCV valve.

Definition

PCV stands for positive crankcase ventilation. The PCV valve is a spring-loaded, one-way valve that ensures continual evacuation of gases from inside the engine.

Function

The PCV valve sends partially burned gases from the engines crankcase (where the power generated from the engine is converted into the energy that drives your car) back into the combustion chamber (where fuel and air are mixed and exploded under pressure), where the gases are re-burned.

Environmental Benefits

The PCV system helps the environment by eliminating crankcase emissions, removing them as a contributing factor to air pollution. It can also help improve fuel mileage by capturing partially-burned gases and returning them to the engine to be re-burned.

Engine Benefits

A PCV valve can help extend the life of your cars engine by preventing the buildup of sludge in the oil and by keeping moisture out of the engine, preventing corrosion from appearing in the engine.

Considerations

According to Yahoo Autos, varnish deposits can clog the PCV valve, so it must be replaced every 50,000 miles or so. Be sure to use a valve specific to your car--the wrong size valve can allow too much or too little airflow.

The oxygen sensor(s) in a vehicle, simply put, are clever devices that monitor the amount of pollution the vehicle dispels from the exhaust system. Although the function of the oxygen sensor goes far beyond this simplistic definition, its main purpose is to monitor and communicate its information to the computer system in a car. When an oxygen sensor fails, your vehicle may have obvious side-effects such as loss of power and decreased fuel efficiency. However, this is not always the case. If a sensor goes bad and there are no noticeable side effects, ignoring the "check engine" light may be detrimental to the vehicle.

Function

The oxygen sensor is a small wired unit that is placed into the exhaust stream of the combustible engine of a vehicle. Its purpose is to monitor the burned fuel to air ratio, also known as the "lambda ratio." There is a perfect lambda ratio in the exhaust of the combustible engine and when it changes, the sensor is effected and transmits this information to the engine management computer via voltage signals. Less air in the lambda ratio will create more leftover fuel after combustion occurs and this will result in a rich mixture. More leftover fuel will create more pollution to the atmosphere and decrease the fuel efficiency of the vehicle. Excess oxygen and less fuel creates a lean mixture. This will result in more nitrogen oxide pollutants and can damage the engine or other expensive exhaust components. In all cases where an O2 sensor fails in a vehicle, the engine management computer will detect the information or lack of information coming from the sensor and trigger the "check engine" light to illuminate on the dashboard to alert the driver.

History

Professor Walter Nernst developed a gas-tight ceramic electrolyte that became conductive at temperatures above 620 degrees in 1899. Because there was little concern for its use back then, it was redeveloped and ingeniously modified in the 1960s by Robert Bosch. When the Environmental Protection Agency mandated stricter exhaust emissions regulations in the 1970s, the lambda sensor or oxygen sensor was introduced to the combustible engines to monitor emissions. The first vehicle to introduce the oxygen sensor was the Volvo 240 model distributed in California in 1977, which also came equipped with the three-way catalyst. By the early 1980s, most all vehicles were mandated to have catalytic converters and oxygen sensors to monitor exhaust emissions.

Types

There are quite a few different types of oxygen sensor, but their primary objective is the same. The first lambda sensor was developed with a single wire (unheated sensor) that simply transmitted voltage to the engine management computer. The problem was that it needed to reach a certain temperature in order to begin to work. In the interim, it would waste fuel and create more pollution. A three and four wire oxygen sensor was later developed (heated sensor) that brought the sensor up to an operating temperature more quickly and thus reduced pollution and increased fuel efficiency. The older single wire or two-wire vehicles may have only had one sensor to monitor, but nowadays, there are at least two heated sensors per vehicle and in some cases as many as four, which makes locating the bad sensor(s) a bit more challenging. The older vehicles sensor would be located near or in the exhaust manifold (upstream). Some cars were then developed with one after the catalytic converter to monitor the exhaust after it was filtered through the converter (downstream). If the vehicle has split cylinders on the engine with dual manifold and more than one converter, more sensors are integrated into the exhaust system to monitor each bank and each converter.

Benefits

The benefits of the oxygen sensor are simple. The combustible engine will perform better, it will have better fuel efficiency and dispel less pollution. However, if a bad oxygen sensor is not addressed, the long-term effects of its ineffectiveness can cause costly damage to the engine or other expensive exhaust components. The decrease in fuel efficiency on an annual basis alone would easily pay for the sensor replacement.

Identification

The location of the sensor is screwed or bolted into the exhaust system, usually in or near the manifold, and as previously mentioned near or after the catalytic converter. A wire and plug attached to the exterior side of the sensor plugs into a wire harness to communicate via voltage to the computer and heat the sensor up to operating temperature. To locate the sensors, follow the exhaust components from the catalytic converter forward to the front exhaust pipe and you would notice small devices screwed directly into the exhaust pipes with a wire attached to them.

Warning

Some shady mechanics and people have discovered ways to trick the oxygen sensor or simply clean the sensor in order to save money and not have to replace them while attempting to pass an emissions inspection. While cleaning a sensor may have a beneficial result, it may be temporary. Tricking the sensor is futile in the long run. The thing to consider when replacing the oxygen sensor is that something else may have caused it to fail. The lean or rich mixture coming from the exhaust has nothing to do with the sensor. The sensor simply monitors it and informs the computer, which then makes adjustments to create the perfect mix. An engine that needs a tune-up or has a leak in the exhaust system can be leading causes of damaging oxygen sensors and just replacing the sensor may not solve the underlying problem.