Ford Mustang (1999-2004) Service Manual: Dual Converter H-Pipe - 4.6L (2V and 4V)

Ford Mustang (1999-2004) Service Manual / Exhaust System / Dual Converter H-Pipe - 4.6L (2V and 4V)

Removal

NOTE: The RH and LH catalytic converters are serviced separately.

1. Raise and support the vehicle. For additional information, refer to Section.

2. CAUTION: When repairing exhaust system or removing the exhaust components, disconnect all heated oxygen sensors (HO2S) (9F472) at the wiring connectors to prevent damage to the heated oxygen sensors and wiring harness.

Disconnect the downstream RH and LH heated oxygen sensor connectors (9F472).

Dual Converter H-Pipe - 4.6L (2V and 4V)

3. Disconnect the two upstream RH and LH catalyst monitor sensor connectors.

Dual Converter H-Pipe - 4.6L (2V and 4V)

4. Remove the dual converter assembly nuts. (RH shown, LH similar.)

Dual Converter H-Pipe - 4.6L (2V and 4V)

5. Remove the RH exhaust manifold flange nuts.

Dual Converter H-Pipe - 4.6L (2V and 4V)

6. Remove the LH exhaust manifold flange nuts.

Dual Converter H-Pipe - 4.6L (2V and 4V)

7. Remove the dual converter H-pipe.

Dual Converter H-Pipe - 4.6L (2V and 4V)

8. If necessary, use the center of the LH flange as a baseline, measure 67 mm (2.68 in) and cut the cross-over pipe.

Dual Converter H-Pipe - 4.6L (2V and 4V)

9. If necessary, use the center of the RH flange as a baseline, measure 83.9 mm (3.35 in) and cut the cross-over pipe.

Installation

1. Position the LH and RH dual converter pipe.

  • Snug the converter-to-manifold nuts.

Dual Converter H-Pipe - 4.6L (2V and 4V)

2. Position the muffler and install the dual converter assembly nuts. (RH shown, LH similar.)

Dual Converter H-Pipe - 4.6L (2V and 4V)

3. If necessary, position the sleeve and clamps. Tighten the clamps to 55 Nm (41 lb-ft).

4. Tighten the four converter-to-manifold nuts.

Dual Converter H-Pipe - 4.6L (2V and 4V)

5. Connect the two upstream RH and LH heated oxygen sensor connectors.

6. Connect the two downstream RH and LH catalyst monitor sensor connectors.

 

    Dual Converter Y-Pipe - 3.8L
    Removal NOTE: The RH and LH catalytic converters are serviceable separately. 1. Raise and support the vehicle. For additional information, refer to Section. 2. CAUTION: When repairing the exhaust sys ...

    Other materials:

    Inspection and Verification
    1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. Visual Inspection Chart Electrical Central junction box (CJB) Fuse 31 (5A) Damaged wiring harness Loose or corroded connections ...

    Connect
    1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent. 3. CAUTION: Use only the new O-ring seals. The use of any O-ring seals other than those specified in ...

    Child restraint and safety belt maintenance
    Inspect the vehicle safety belts and child safety seat systems periodically to make sure they work properly and are not damaged. Inspect the vehicle and child seat safety belts to make sure there are no nicks, tears or cuts. Replace if necessary. All vehicle ...