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XJ
EXHAUST SYSTEM
11 - 1
EXHAUST SYSTEM
CONTENTS
page
page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS AND TESTING
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . .
1
1
2
3
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 4
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
EXHAUST SYSTEM
The basic exhaust system consists of an engine
exhaust manifold, exhaust pipe with oxygen sensor,
catalytic converter with oxygen sensor, muffler and
exhaust tailpipe (Fig. 1).
The 4.0L engines use a seal between the engine
exhaust 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-
tionable noises originating from the engine or body.
When inspecting an exhaust system, critically
inspect 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
repair.
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
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
CATALYTIC CONVERTER
The stainless steel catalytic converter body is
designed 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
unburned 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 Exhaust System—2.5L/4.0L
The exhaust system uses a single muffler with a cat-
alytic converter consisting of dual ceramic monoliths.
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EXHAUST SYSTEM
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DIAGNOSIS AND TESTING
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
POSSIBLE CAUSE
1. Leaks at pipe joints.
2. Rusted or blown out muffler.
3. Broken or rusted out exhaust
pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Catalytic converter rusted or
blown out.
8. Restriction in exhaust system.
CORRECTION
1. Tighten clamps/bolts at leaking
joints.
2. Replace muffler. Inspect exhaust
system.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching
nuts/bolts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Replace catalytic converter assy.
8. Remove restriction, if possible.
Replace restricted part if necessary.
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
REMOVAL AND INSTALLATION
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(6) Remove the clamp nuts and clamp (Fig. 2). 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. 2). 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.
2).
(4) Install the rear crossmember. Install and
tighten the four (4) crossmember to rear mount nuts
to 22 N·m (16 ft. lbs.) Install and tighten the cross-
member to sill bolts to 42 N·m (31 ft. lbs.) torque.
Remove the support from the transmission.
(5) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 27
N·m (20 ft. lbs.) torque.
(6) Lower the vehicle.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant (Fig. 2). Allow 5 minutes for penetration.
(3) Disconnect the oxygen sensor connector (Fig.
3).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold. Discard the seal (4.0L engine,
only).
(5) Support the transmission and remove the rear
crossmember.
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REMOVAL AND INSTALLATION (Continued)
EXHAUST SYSTEM
11 - 3
Fig. 2 Exhaust Pipe Removal—2.5L/4.0L
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the clamps from the catalytic converter
and muffler connection (Fig. 4).
(3) Disconnect and remove the oxygen sensor from
the catalytic converter.
(4) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal
becomes cherry red.
(5) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(6) Disconnect the exhaust pipe from the catalytic
converter (Fig. 4). If needed, heat up the pipes to sep-
arate.
Fig. 3 Oxygen Sensor Location—2.5L/4.0L
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
INSTALLATION
(1) Connect the catalytic converter to the exhaust
pipe and the muffler/tailpipe assy. (Fig. 4). 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.
CATALYTIC CONVERTER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
11 - 4
EXHAUST SYSTEM
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REMOVAL AND INSTALLATION (Continued)
(3) Remove the front exhaust clamp from the cat-
alytic converter and muffler connection (Fig. 6).
Fig. 4 Catalytic Converter to Muffler and Exhaust
Pipe Connection
(3) Install a new clamp at the muffler and cata-
lytic converter connection (Fig. 4). Tighten the clamp
nut to 61 N·m (45 ft. lbs.) torque.
(4) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 27
N·m (20 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.
Fig. 5 Front Exhaust Tailpipe Hanger
MUFFLER AND EXHAUST TAILPIPE
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sensor.
Fig. 6 Catalytic Converter to Muffler Connection
(4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal
becomes cherry red.
(5) While the metal is still cherry red, remove the
exhaust muffler/tailpipe assembly from the catalytic
converter.
(6) Slide the muffler/tailpipe assy. rearward and
out of the rear exhaust tailpipe mounting bracket
(Fig. 7).
(7) Remove the muffler from the exhaust tailpipe:
•
To remove an original equipment exhaust muf-
fler/tailpipe combination, cut the exhaust tailpipe
REMOVAL
(1) Raise and support the vehicle.
(2) Disconnect front tailpipe hanger from the insu-
lator (Fig. 5).
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REMOVAL AND INSTALLATION (Continued)
EXHAUST SYSTEM
11 - 5
(6) Align the tailpipe and install a new clamp at
the muffler to tailpipe connection.
(7) Tighten the muffler to tailpipe clamp to 61 N·m
(45 ft. lbs.)
(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.
SPECIFICATIONS
TORQUE SPECIFICATIONS
Description
Torque
Catalytic Converter/Exhaust Pipe
Exhaust Clamp Nut . . . . . . . . . . 61 N·m (45 ft. lbs.)
Crossmember to Sill
Bolts . . . . . . . . . . . . . . . . . . . . . . 42 N·m (31 ft. lbs.)
Crossmember to Transmission Mount
Nuts . . . . . . . . . . . . . . . . . . . . . . 22 N·m (16 ft. lbs.)
Exhaust Pipe to Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Exhaust Manifold–2.5L Engine
Bolt #1 . . . . . . . . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Exhaust Manifold–2.5L Engine
Nuts #6&7 . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Exhaust Manifold–4.0L Engine
Nuts #6&7 . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Bolt #3 . . . . . . . . . . . . . . . . . . . . 33 N·m (24 ft. lbs.)
Intake Manifold–2.5L Engine
Bolt #2–5 . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Intake & Exhaust Manifold–2.5L Engine
Bolts #2–5 . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Intake & Exhaust Manifold–4.0L Engine
Nuts/Bolts #1,2,4,5,8–11 . . . . . . . 33 N·m (24 ft. lbs.)
Muffler to Catalytic Converter
Exhaust Clamp Nut . . . . . . . . . . 61 N·m (45 ft. lbs.)
Oxygen Sensors
Nut . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft. lbs.)
Rear Tail Pipe Hanger
Nuts . . . . . . . . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Fig. 7 Rear Exhaust Tailpipe Mounting Bracket
close to the muffler. Collapse the part remaining in
the muffler and remove.
•
To remove a service exhaust tailpipe/muffler
combination, apply heat until the metal becomes
cherry red. Remove the exhaust tailpipe/muffler
clamp and twist the exhaust tailpipe out of the muf-
fler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nut finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe mounting bracket. Make
sure that the exhaust tailpipe has sufficient clear-
ance from the floor pan.
(4) Install front tailpipe hanger into the insulator
(Fig. 5).
(5) Align the muffler and tighten the nuts on the
muffler-to-catalytic converter clamp to 61 N·m (45 ft.
lbs.) torque (Fig. 6).

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