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:

    Refrigerant Lines
    The condenser to evaporator tube (19835) contains the high pressure liquid refrigerant upstream of the evaporator core orifice. The A/C manifold and tube (19D734) is attached to the A/C compressor, is sealed with O-ring seals, and has the following features ...

    Disc and Pressure Plate - 3.8L and 4.6L (2V) Engines
    Special Tool(s) Clutch Aligner 308-020 (T74P-7137-K) Material Item Specification Premium Long Life Grease XG-1-C ESA-M1C75-B 1. Remove the transmission. 2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate ...

    Exceptions To Normal Schedule
    Yellow Coolant Change coolant at 5 years or 160,000 km (100,000 miles) of the vehicle's life, whichever comes first. After the initial change, change coolant every 3 years or 80,000 km (50,000 miles) thereafter. Natural Gas and Propane Vehicles Insp ...