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EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 1
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
page
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . . 2
SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10
EXHAUST SYSTEM
GENERAL INFORMATION
The basic exhaust system consists of an engine ex-
haust manifold, exhaust pipe with oxygen sensor, cat-
alytic converter, exhaust heat shield(s), muffler and
exhaust tailpipe (Fig. 1).
tionable noises originating from the engine or body.
When inspecting an exhaust system, critically in-
spect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to re-
pair.
When replacement is required, use original equip-
ment parts (or their equivalent). This will assure
proper alignment and provide acceptable exhaust
noise levels.
CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem floor pan exhaust heat shields. Light overspray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
CATALYTIC CONVERTER
The stainless steel catalytic converter body is de-
signed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If un-
burned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid contami-
nating the catalyst core.
Fig. 1 Typical Exhaust System
The exhaust system uses a single muffler with a
single monolithic-type catalytic converter.
The 4.0L engines use a seal between the engine ex-
haust manifold and exhaust pipe to assure a tight
seal and strain free connections.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it may amplify objec-
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both the
vehicle and the environment from the high tempera-
tures developed by the catalytic converter. The cata-
lytic converter releases additional heat into the
exhaust system. Under severe operating conditions,
the temperature increases in the area of the con-
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EXHAUST SYSTEM AND INTAKE MANIFOLD
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DO NOT allow the engine to operate at fast idle for
extended periods (over 5 minutes). This condition
may result in excessive temperatures in the exhaust
system and on the floor pan.
verter. Such conditions can exist when the engine
misfires or otherwise does not operate at peak effi-
ciency.
DO NOT remove spark plug wires from plugs or by
any other means short out cylinders. Failure of the
catalytic converter can occur due to a temperature
increase caused by unburned fuel passing through
the converter.
EXHAUST SYSTEM DIAGNOSIS
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EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 3
SERVICE PROCEDURES
INDEX
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Catalytic Converter . . . . . . . . . . . . . . .
Engine Exhaust Manifold—2.5L Engine
Engine Exhaust Manifold—4.0L Engine
Exhaust Pipe—XJ Vehicles . . . . . . . . .
Exhaust Pipe—YJ Vehicles . . . . . . . . .
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Intake Manifold—2.5L Engine . . . . . . . . .
Intake Manifold—4.0L Engine . . . . . . . . .
Muffler and Exhaust Tailpipe—XJ Vehicles
Muffler and Exhaust Tailpipe—YJ Vehicles
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EXHAUST PIPE—XJ VEHICLES
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lu-
bricant (Fig. 1). Allow 5 minutes for penetration.
Fig. 2 Oxygen Sensor
(5) Support the transmission and remove the rear
crossmember.
(6) Remove the clamp nuts and clamp (Fig. 3). To
remove the exhaust pipe from the catalytic converter,
apply heat until the metal becomes cherry red. Dis-
connect the exhaust pipe from the catalytic converter
(Fig. 3). Remove the exhaust pipe.
Fig. 1 Exhaust Pipe-to-Engine Exhaust Manifold
Nuts
(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 2).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal (4.0L engine,
only).
Fig. 3 Exhaust Pipe-to-Catalytic Converter
Connection
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EXHAUST SYSTEM AND INTAKE MANIFOLD
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(3) Remove the oxygen sensor from the exhaust
pipe (Fig. 2).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold.
(5) Disconnect the exhaust pipe from the catalytic
converter and slide the pipe out of the transmission
torque arm insulator (Fig. 5). Remove the exhaust
pipe.
INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
all parts.
(2) Use a new clamp and tighten the nuts to 61
N m (45 ft. lbs.) torque.
(3) Connect the exhaust pipe to the engine exhaust
manifold. Install a new seal between the exhaust
manifold and the exhaust pipe (4.0L engine, only).
Tighten the nuts to 31 N m (23 ft. lbs.) torque (Fig.
1).
(3) Install the rear crossmember. Tighten the
crossmember-to-sill bolts to 41 N m (30 ft. lbs.)
torque. Remove the support from the transmission.
(4) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
N m (35 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
EXHAUST PIPE—YJ VEHICLES
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
Fig. 5 Exhaust Pipe-to-Catalytic Converter
Connection—YJ Vehicles
INSTALLATION
(1) Slide the exhaust pipe into the transmission
torque arm insulator and onto the catalytic converter
(Fig. 5).
(2) Clean the mating surface of the engine exhaust
manifold flange.
(3) Connect the exhaust pipe to the engine exhaust
manifold using new nuts. DO NOT tighten the nuts.
(4) Align the exhaust pipe.
(5) Use a new clamp at the exhaust pipe to cata-
lytic converter connection and tighten the nuts to 61
N m (45 ft. lbs.) torque.
(6) Tighten the exhaust pipe-to-engine exhaust
manifold nuts to 31 N m (23 ft. lbs.) torque.
(7) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 48
N m (35 ft. lbs.) torque.
(8) Lower the vehicle.
(9) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve lu-
bricant (Fig. 4). Allow 5 minutes for penetration.
CATALYTIC CONVERTER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
Fig. 4 Exhaust Pipe-to-Engine Exhaust Manifold
Bolts and Nuts
REMOVAL
(1) Raise and support the vehicle.
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(2) Remove the clamp from the catalytic converter
and muffler connection (Fig. 6).
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 5
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front muffler clamp from the cata-
lytic converter and muffler connection (Fig. 6).
(3) Remove the rear exhaust tailpipe hanger clamp
(Fig. 7) and remove the exhaust tailpipe from the
front exhaust tailpipe hanger (Fig. 8).
Fig. 6 Catalytic Converter-to-Muffler Connection
(3) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal
becomes cherry red.
(4) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(5) Disconnect the exhaust pipe from the catalytic
converter (Figs. 3 and 5). If needed, heat up the pipes
to separate.
Fig. 7 Rear Exhaust Tailpipe Hanger Clamp
INSTALLATION
(1) Connect the catalytic converter to the exhaust
pipe (Figs. 3 and 5). Use a new clamp and tighten
the nuts to 61 N m (45 ft. lbs.) torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install a new clamp at the muffler and catalytic
converter connection (Fig. 6). Tighten the clamp nuts
to 61 N m (45 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPE—XJ VEHICLES
All original
factured with
fler. Service
tailpipes are
gether.
equipment exhaust systems are manu-
the exhaust tailpipe welded to the muf-
replacement mufflers and exhaust
either clamped together or welded to-
Fig. 8 Front Exhaust Tailpipe Hanger
(4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal be-
comes cherry red.
(5) While the metal is still cherry red, remove the
exhaust tailpipe/muffler assembly from the catalytic
converter.
(6) Remove the exhaust tailpipe from the muffler:
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.

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