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

TJ
EXHAUST PIPE (Continued)
(6) Slide exhaust pipe foward until exhaust pipe
hanger disengages
Remove exhaust pipe and catalytic converter from
vehicle.
Fig. 5 Exhaust Pipe and Calalytic Converter - 2.4L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
REMOVAL — 4.0L
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.
from transmission
(3) Remove the oxygen sensors from the exhaust
support. pipe and the catalytic converter.
(4) Disconnect the exhaust pipe from the engine
exhaust manifold (Fig. 6).
(5) Remove catalytic converter to muffler flange
retaining nuts (Fig. 6).
(6) Slide exhaust pipe foward until exhaust pipe
hanger disengages
Remove exhaust pipe and catalytic converter from
vehicle.
Fig. 6 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 exhaust pipe and catalytic converter
into vehicle.
(2) Insert exhaust pipe hanger into transmission
support (Fig. 5).
(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. 5).
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.).
(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.
EXHAUST SYSTEM
from transmission
11 - 7
support.