Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Jeep Cherokee XJ 1997.1999-2001 Approved 1999 XJ Jeep Cherokee EXJ_11

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EXJ_11

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XJ EXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM
CONTENTS

page page

GENERAL INFORMATION EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 1 MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 4
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS
DIAGNOSIS AND TESTING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 3

GENERAL INFORMATION The 4.0L engines use a seal between the engine
exhaust manifold and exhaust pipe to assure a tight
EXHAUST SYSTEM seal and strain free connections.
The basic exhaust system consists of an engine The exhaust system must be properly aligned to
exhaust manifold, exhaust pipe with oxygen sensor, prevent stress, leakage and body contact. If the sys-
catalytic converter with oxygen sensor, muffler and tem contacts any body panel, it may amplify objec-
exhaust tailpipe (Fig. 1). 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.
Fig. 1 Exhaust System--2.5L/4.0L Unleaded gasoline must be used to avoid contami-
The exhaust system uses a single muffler with a cat- nating the catalyst core.
alytic converter consisting of dual ceramic monoliths.
11 - 2 EXHAUST SYSTEM XJ

DIAGNOSIS AND TESTING

EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART

CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
LEAKING EXHAUST GASES joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust 3. Replace exhaust pipe.
pipe.
4. Exhaust pipe leaking at manifold 4. Tighten/replace flange attaching
flange. nuts/bolts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten exhaust manifold to
and cylinder head. cylinder head bolts.
7. Catalytic converter rusted or 7. Replace catalytic converter assy.
blown out.
8. Restriction in exhaust system. 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 (6) Remove the clamp nuts and clamp (Fig. 2). To
remove the exhaust pipe from the catalytic converter,
EXHAUST PIPE apply heat until the metal becomes cherry red. Dis-
connect the exhaust pipe from the catalytic converter
WARNING: IF TORCHES ARE USED WHEN WORK- (Fig. 2). Remove the exhaust pipe.
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES. INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
CAUTION: When servicing exhaust system compo- all parts.
nents, disconnect the oxygen sensor connector. (2) Use a new clamp and tighten the nuts to 61
Allowing the exhaust system to hang by the oxygen N

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