Ford Mustang (1999-2004) Service Manual: 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).

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

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

5. Remove the RH exhaust manifold flange nuts.

6. Remove the LH exhaust manifold flange nuts.

7. Remove the dual converter H-pipe.

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.

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.

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

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.

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

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