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TJ
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
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 .
REMOVAL
(1) Raise and support the vehicle .
(2) Saturate the studs and nuts with heat valve
lubricant. Allow 5 minutes for penetration (Fig. 3)
(Fig. 4).
(3) Remove the oxygen sensors from the exhaust
pipe and the catalytic converter (Fig . 3) (Fig. 4).
(4) Disconnect the exhaust pipe from the engine
exhaust manifold . Discard the seal (4.01, engine,
only) (Fig. 4).-
(5) Support the transmission and remove the rear
crossmember.
(6) Remove the clamp from the catalytic converter
and muffler connection.
(7) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal
becomes cherry red.
(8) While the metal is still cherry red, twist the
muffler assembly back and forth to seperate it from
the catalytic converter.
EXHAUST SYSTEM AND INTAKE MANIFOLD
11-3
Exhaust System Diagnosis
J9311-13
Fig. 3 Exhaust Pipe with Catalytic Converter 2.5 L
Engine
INSTALLATION
(1) Assemble
catalytic
converter
and muffler
loosely to permit proper alignment of all parts .
(2) Use a new clamp and tighten the nut to 71
N-m (52 ft. lbs.) torque .
(3) Connect the exhaust pipe to the engine exhaust
manifold. Install a new seal between the exhaust
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE
1 . Leaks at pipe joints .
1 . Tighten clamps at leaking joints .
2. Burned or blown-out muffler.
2. Replace muffler assembly. Check
exhaust system .
3 . Burned or rusted-out exhaust pipe.
3 . Replace exhaust pipe .
4. Exhaust pipe leaking at manifold flange.
4 . Tighten connection attaching nuts.
5. Exhaust manifold cracked or broken .
5 . Replace exhaust manifold .
6. Leak between exhaust manifold and
6. Tighten exhaust manifold to cylinder
cylinder head .
head stud nuts or bolts.
7. Restriction in muffler or tail pipe .
7. Remove restriction, if possible. Replace
muffler or tail pipe, as necessary .
LEAKING EXHAUST GASES
1 . Leaks at pipe joints .
1 . Tighten clamps at leaking joints .
2. Damaged or improperly installed gaskets .
2. Replace gaskets, as necessary .
ENGINE HARD TO WARM UP
1 . Blocked crossover passage in intake
1 . Remove restriction or replace intake
OR WILL NOT RETURN TO
manifold .
manifold .
NORMAL IDLE
2.
Thermostat broken .
2 . Replace thermostat.
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Troubleshooting
