Installation - 2.4L; Installation - 4.0L; Exhaust Pipe; Removal - 2.4L - Chrysler Vehicle User Manual

11 - 6 EXHAUST SYSTEM
CATALYTIC CONVERTER (Continued)
(1) Raise and support the vehicle.
(2) Saturate the studs and nuts with a Mopar
rust penetrant. Allow 5 minutes for penetration.
(3) Remove the oxygen sensors from the exhaust
pipe and the catalytic converter.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold (Fig. 4).
(5) Remove mini catalytic converter flange retain-
ing nuts (Fig. 4).
(6) Slide exhaust pipe foward until exhaust pipe
hanger disengages
Remove exhaust pipe and catalytic converter from
vehicle.
Fig. 4 Exhaust Pipe and Catalytic Converter - 4.0L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER

4 - EXHAUST PIPE

INSTALLATION
INSTALLATION – 2.4L
(1) Position the mini catalytic converter assembly
onto the exhaust pipe flange and the exhaust mani-
fold. Tighten the nuts to 31 N·m (23 ft.lbs.) torque.
Tighten the flange nuts to 28 N·m (21 ft. lbs.).
(2) Connect oxygen sensor wiring.
(3) Lower the vehicle.
(4) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
INSTALLATION — 4.0L
(1) Position exhaust pipe and catalytic converter
into vehicle.
(2) Insert exhaust pipe hanger into transmission
support (Fig. 4).
from transmission
(3) Install exhaust pipe onto exhaust manifold DO
NOT tighten bolts at this time.
(4) Position muffler flange onto catalytic converter
flange and install retaining bolts and nuts (Fig. 4).
DO NOT tighten nuts at this time.
(5) Make sure the exhaust system is aligned and
has the proper clearance. The minimum clearance is
25mm (1 inch).
(6) Tighten muffler to catalytic converter flange
retaining nuts to 28.5 N·m (21 ft. lbs.).
support. (7) Tighten exhaust pipe to exhaust manifold
mounting bolts to 31 N·m (23 ft. lbs.).
(8) Install the oxygen sensors in the exhaust pipe
and catalytic converter.
(9) Lower vehicle.
(10) Start engine check for leaks.
EXHAUST PIPE
REMOVAL
REMOVAL — 2.4L
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
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(s).
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
(1) Raise and support the vehicle.
(2) Saturate the studs and nuts with a Mopar
rust penetrant. Allow 5 minutes for penetration.
(3) Remove the oxygen sensors from the exhaust
pipe and the catalytic converter.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold (Fig. 5).
(5) Remove catalytic converter to muffler flange
retaining nuts (Fig. 5).
TJ