Section 09-00: Exhaust System
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

 WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION.

Catalytic Converter

 

5.0L HO Engine

 

Removal

  1. Raise vehicle. Refer to Section 00-02.
  1. Disconnect air injection tube from the converter assembly. Support muffler with wire.
  1. Remove catalytic converter to exhaust manifold retaining nuts.
  1. Remove muffler inlet pipes to converter retaining nuts.
  1. Remove converter.
  1. Replace any damaged parts.
 

Installation

  1. Insert converter hanger rods into the hanger brackets.
  1. Position converter to exhaust manifold studs and install retaining nuts. Do not tighten nuts. Remove wire support.
  1. Position muffler inlet flanges to converter outlet flanges and install retaining nuts. Do not tighten nuts. Remove wire support.
  1. Align exhaust system to specification, refer to appropriate illustration.
  1. With exhaust system aligned:
    1. Tighten converter-to-exhaust manifold nuts to 21.7-40.6 Nm (16-30 lb-ft).
    1. Tighten muffler inlet pipes-to-converter outlet flanges retaining nuts to 20.3-40.6 Nm (15-30 lb-ft).
  1. Attach air tube.
  1. Check system for leaks and lower vehicle.
 

2.3L Engine

 

Removal

  1. Raise vehicle. Refer to Section 00-02.
  1. Support muffler with wire.
  1. Remove converter inlet pipe flange-to-exhaust manifold retaining nuts.
  1. Remove converter outlet flange to muffler retaining nuts.
  1. Remove converter.
 

Installation

  1. Clean exhaust manifold and catalytic converter flange seat.
  1. Insert converter hanger rod into front bracket insulator.
  1. Position inlet pipe to manifold and install, but do not tighten retaining nuts.
  1. Remove wire support from muffler assembly and install muffler inlet flange to converter outlet flange. Loosely install retaining nuts.
  1. Align exhaust system to proper clearance specifications, as shown in the appropriate illustration.
  1. Starting at the front of the system, tighten all nuts and bolts to the specifications shown in the appropriate illustration.
  1. Check exhaust system for leaks.


5.0L Engine Dual Exhaust






2.3L Engine Single Exhaust