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Exhaust System and Intake Manifold

Exhaust System and Intake Manifold

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Published by aw12345

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Published by: aw12345 on Aug 17, 2009
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10/29/2011

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EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page page
GENERAL INFORMATION
CATALYTICCONVERTER................. 3EXHAUSTHEATSHIELDS................ 3EXHAUSTSYSTEM..................... 1
DIAGNOSIS AND TESTING
EXHAUSTSYSTEM..................... 3
REMOVAL AND INSTALLATION
SPECIFICATIONS
TORQUESPECIFICATIONS................ 9
GENERAL INFORMATION
EXHAUST SYSTEM
The basic exhaust system consists of an engineexhaust manifold, exhaust pipe with oxygen sensor,catalytic converter with oxygen sensor, exhaust heatshield(s), muffler and exhaust tailpipe (Fig. 1) (Fig.2).The exhaust system uses a single muffler with acatalytic converter consisting of dual ceramic mono-liths.The 4.0L engines use a seal between the engineexhaust manifold and exhaust pipe to assure a tightseal and strain free connections (Fig. 2).The exhaust system must be properly aligned toprevent stress, leakage and body contact. If the sys-tem contacts any body panel, it may amplify objec-tionable noises originating from the engine or body.When inspecting an exhaust system, criticallyinspect for cracked or loose joints, stripped screw orbolt threads, corrosion damage and worn, cracked orbroken hangers. Replace all components that arebadly corroded or damaged. DO NOT attempt torepair.When replacement is required, use original equip-ment parts (or their equivalent). This will assureproper alignment and provide acceptable exhaustnoise levels.
CAUTION: Avoid application of rust preventioncompounds or undercoating materials to exhaustsystem floor pan exhaust heat shields. Light overspray near the edges is permitted. Application ofcoating will result in excessive floor pan tempera-tures and objectionable fumes.
TJ
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
 
Fig. 1 Exhaust System—2.5L EnginFig. 2 Exhaust System—4.0L Engin
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD
TJ
GENERAL INFORMATION (Continued)
 
CATALYTIC CONVERTER
The stainless steel catalytic converter body isdesigned to last the life of the vehicle. Excessive heatcan 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 mayoccur. If a converter is heat-damaged, correct thecause of the damage at the same time the converteris replaced. Also, inspect all other components of theexhaust system for heat damage.Unleaded gasoline must be used to avoid contami-nating the catalyst core.
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect boththe vehicle and the environment from the high tem-peratures developed by the catalytic converter. Thecatalytic converter releases additional heat into theexhaust system. Under severe operating conditions,the temperature increases in the area of the con-verter. Such conditions can exist when the enginemisfires or otherwise does not operate at peak effi-ciency.DO NOT remove spark plug wires from plugs or byany other means short out cylinders. Failure of thecatalytic converter can occur due to a temperatureincrease caused by unburned fuel passing throughthe converter.DO NOT allow the engine to operate at fast idle forextended periods (over 5 minutes). This conditionmay result in excessive temperatures in the exhaustsystem and on the floor pan.
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART 
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE ORLEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking joints.2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaustsystem.3. Broken or rusted out exhaustpipe.3. Replace exhaust pipe.4. Exhaust pipe leaking at manifoldflange.4. Tighten/replace flange attachingnuts/bolts.5. Exhaust manifold cracked orbroken.5. Replace exhaust manifold.6. Leak between exhaust manifoldand cylinder head.6. Tighten exhaust manifold tocylinder head bolts.7. Catalytic converter rusted orblown out.7. Replace catalytic converter assy.8. Restriction in exhaust system. 8. Remove restriction, if possible.Replace restricted part if necessary.
CAUTION: When servicing and replacing exhaustsystem components, disconnect the oxygen sensorconnector(s). Allowing the exhaust to hang by theoxygen sensor wires will damage the harnessand/or sensor.
TJ
EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
GENERAL INFORMATION (Continued)

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