Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1988-1989.1993-1995 Approved 1994 XJ Jeep Cherokee 94XJ_11
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J EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10
EXHAUST SYSTEM
GENERAL INFORMATION tem contacts any body panel, it may amplify objec-
The basic exhaust system consists of an engine ex- tionable noises originating from the engine or body.
haust manifold, exhaust pipe with oxygen sensor, When inspecting an exhaust system, critically in-
catalytic converter, exhaust heat shield(s), muffler spect for cracked or loose joints, stripped screw or
and exhaust tailpipe (Fig. 1). 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
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light overs-
pray 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 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-
Fig. 1 Typical Exhaust System nating the catalyst core.
The exhaust system uses a single muffler with a
single monolithic-type catalytic converter. EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both the
The 4.0L engines use a seal between the engine ex-
vehicle and the environment from the high tempera-
haust manifold and exhaust pipe to assure a tight
tures developed by the catalytic converter. The cata-
seal and strain free connections.
lytic converter releases additional heat into the
The exhaust system must be properly aligned to
exhaust system. Under severe operating conditions,
prevent stress, leakage and body contact. If the sys-
the temperature increases in the area of the con-
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD J
verter. Such conditions can exist when the engine increase caused by unburned fuel passing through
misfires or otherwise does not operate at peak effi- the converter.
ciency. DO NOT allow the engine to operate at fast idle for
DO NOT remove spark plug wires from plugs or by extended periods (over 5 minutes). This condition
any other means short out cylinders. Failure of the may result in excessive temperatures in the exhaust
catalytic converter can occur due to a temperature system and on the floor pan.
EXHAUST SYSTEM DIAGNOSIS
J EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
SERVICE PROCEDURES
INDEX
page page
Catalytic Converter . . . . . . . . . . . . . . .. . . . . . . . . 5 Intake Manifold--2.5L Engine . . . . . . . . . ... . . . . 8
Engine Exhaust Manifold--2.5L Engine . . . . . . . . . 7 Intake Manifold--4.0L Engine . . . . . . . . . ... . . . . 9
Engine Exhaust Manifold--4.0L Engine . . . . . . . . . 7 Muffler and Exhaust Tailpipe--XJ Vehicles .. . . . . 5
Exhaust Pipe--XJ Vehicles . . . . . . . . .. . . . . . . . . 3 Muffler and Exhaust Tailpipe--YJ Vehicles .. . . . . 6
Exhaust Pipe--YJ Vehicles . . . . . . . . .. . . . . . . . . 4
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
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). Fig. 3 Exhaust Pipe-to-Catalytic Converter
(4) Disconnect the exhaust pipe from the engine Connection
exhaust manifold. Discard the seal (4.0L engine, CLEANING
only). Clean the mating surfaces of the engine exhaust
(5) Support the transmission and remove the manifold flange and the exhaust pipe.
transmission support crossmember.
(6) Remove the clamp nuts and clamp (Fig. 3). To
remove the exhaust pipe from the catalytic converter,
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD J
INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
all parts.
(2) Use a new clamp at the exhaust pipe to cata-
lytic converter connection and tighten the nuts to 61
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