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Exhaust Flexible Pipe - 2.5L > < Catalytic Converter - 2.5L

Cougar 1999 (08.1998-01.2001)

Exhaust System - Exhaust Flexible Pipe—2.0L Cougar 1999 (08/1998-01/2001)
Removal and Installation

Materials
Name
Specification
Lubricant
ESE-M99B144-B 
Anti-seize grease
SAM - 1C907A 

Removal

Vehicles built up to 05/1999
  1. Remove the oil level indicator.
All vehicles
  1. Remove the heat shield.

  1. Disconnect the flexible pipe from the exhaust manifold.
    • Remove and discard the gasket and nuts.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Disconnect the heated oxygen (H02S) sensor electrical connector.

  1. Remove the H02S.

  1. CAUTION:
    CAUTION:Over bending of the flexible pipe may cause damage resulting in failure.
    Support the flexible pipe with a support wrap or suitable splint assembly.

  1. Disconnect the flexible pipe from the oil pan.

  1. Remove the flexible pipe.
    1. Remove the nuts.
    1. Detach the hanger insulator.
    • Discard the gasket and nuts.

Installation

All vehicles
  1. CAUTION:
    CAUTION:The hanger insulators are constructed of a special material. Use only correct specification insulators.
    NOTE:
    NOTE:Do not fully tighten the nuts at this stage.
    Install the flexible pipe.
    1. Install the nuts.
    1. Attach the hanger insulator.
    • Check the hanger insulator for damage and fatigue. Install a new hanger insulator as required.
    • When installing exhaust hanger insulators use lubricant meeting Ford specification.
  1. Lower the vehicle.

  1. Connect the flexible pipe to the exhaust manifold.
    • Use a new gasket and studs.
Vehicles built up to 05/1999
  1. Install the oil level indicator.
All vehicles
  1. Install the heat shield.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Tighten the nuts.

  1. Connect the flexible pipe to the oil pan.

  1. Install the H02S.

  1. Connect the H02S electrical connector.
  1. Remove the flexible pipe support.
  1. Lower the vehicle.

Exhaust Flexible Pipe - 2.5L > < Catalytic Converter - 2.5L