Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 344 (EXHAUST SYSTEM)DIAGNOSIS AND TESTINGEXHAUST SYSTEMINSPECTION AND VERIFICATION
2009 Ford Fusion SEL, 3.0 1, FWD
Inspection and Verification
2009 Ford Fusion SEL, 3.0 1, FWDSECTION Inspection and Verification
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
- Verify the customer concern.
- Visually inspect the components of the exhaust system and related controls that may affect exhaust gas quality or loss of power.
- Visually inspect for obvious signs of mechanical damage.VISUAL INSPECTION CHART
Mechanical - Exhaust pipe pinched or crushed
- Damaged muffler
- Broken or damaged exhaust hanger brackets
- Damaged catalytic converter
- Cracked exhaust manifold
- Loose or damaged heat shields
- Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to specification.
- If the fault is not visually evident, determine the symptom. GO to SYMPTOM CHART .
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.