Jeep cherokee 2000 Service Manual page 815

XJ
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.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with Mopar Rust
Penetrant (Fig. 7) (Fig. 8). Allow 5 minutes for pene-
tration.
Fig. 7 Exhaust Pipe Removal—2.5L
1 – NUT
2 – TRANSMISSION SUPPORT
3 – MINI CATALYTIC CONVERTER
4 – EXHAUST PIPE
5 – EXHAUST MANIFOLD
(3) Disconnect the oxygen sensor connector(s).
(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.
(6) Remove the clamp nuts and clamp. To remove
the exhaust pipe from the catalytic converter, apply
heat until the metal becomes cherry red. Disconnect
Fig. 8 Exhaust Pipe Removal—4.0L
1 – NUT
2 – EXHAUST MANIFOLD
3 – TRANSMISSION SUPPORT
4 – EXHAUST PIPE
5 – MINI CATALYTIC CONVERTER
6 – BOLT
the exhaust pipe from the catalytic converter.
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 (Fig. 7) (Fig. 8). 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.
(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) Carefully coat the threads on the oxygen sen-
sor(s) with anti-seize compound. Install the sensor
and tighten the nut to 27 N·m (20 ft. lbs.) torque.
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
EXHAUST SYSTEM 11 - 5