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FOLD (RIGHT)
MANI-
MUFFLER
EXHAUST PIPE TAILPIPE CATALYTIC
EXHAUST
FOLD
VERTER
CON-
(LEFT)
MANI-
page page
GENERAL INFORMATION
EXHAUST SYSTEM
The basic exhaust system consists of exhaust man-
ifold(s), exhaust pipe with oxygen sensor, catalytic
converter, heat shield(s), muffler and tailpipe (Fig. 1)
or (Fig. 2).
CATALYTIC CONVERTER
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can 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 may
occur. If a converter is heat-damaged, correct the
cause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage. Fig. 3 Front Floor Pan Heat Shield
Unleaded gasoline must be used to avoid contami-
nating the catalyst core.
DO NOT remove spark plug wires from plugs or by
any other means short out cylinders. Failure of the
catalytic converter can occur due to a temperature
increase caused by unburned fuel passing through
the converter.
DO NOT allow the engine to operate at fast idle for
extended periods (over 5 minutes). This condition
may result in excessive temperatures in the exhaust
system and on the floor pan.
HEAT SHIELDS
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed by the catalytic converter (Fig. 3) (Fig. 4).
The catalytic converter releases additional heat into
the exhaust system. Under severe operating condi-
tions, the temperature increases in the area of the
converter. Such conditions can exist when the engine
misfires or otherwise does not operate at peak effi-
ciency.
REMOVAL AND INSTALLATION (6) Disconnect the exhaust pipe hanger from the
rear mount bracket insulator (Fig. 7).
EXHAUST PIPE (7) Remove the exhaust pipe.
REMOVAL INSTALLATION
(1) Position the exhaust pipe onto the catalytic
WARNING: IF TORCHES ARE USED WHEN WORK- converter.
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW (2) Connect the exhaust pipe hanger to the rear
THE FLAME NEAR THE FUEL LINES. mount bracket insulator.
(3) On 4.0L engines, install a new seal between
(1) Raise and support the vehicle. the exhaust pipe and the engine exhaust manifold
(2) Saturate the bolts and nuts with heat valve (Fig. 5). Connect the exhaust pipe to the engine
lubricant. Allow 5 minutes for penetration. exhaust manifold. Tighten the nuts to 31 N·m (23 ft.
(3) Remove the oxygen sensor from the exhaust lbs.) torque.
pipe (Fig. 5) (Fig. 6). (4) Position the exhaust clamp over the exhaust
(4) Disconnect the exhaust pipe from the engine pipe/catalytic converter connection (Fig. 5) (Fig. 6).
exhaust manifold. On 4.0L engines, discard the Tighten the nuts to 61 N·m (45 ft. lbs.) torque.
exhaust manifold seal (Fig. 5). (5) Coat the oxygen sensor with anti-seize com-
(a) Heat the exhaust pipe and catalytic con- pound. Install the sensor and tighten the nut to 48
verter connection with an torch until the metal N·m (35 ft. lbs.) torque.
becomes cherry red. (6) Lower the vehicle.
(b) While the metal is still cherry red, twist the (7) Start the engine and inspect for exhaust leaks
exhaust pipe back and forth to separate it from the and exhaust system contact with the body panels.
catalytic converter. Adjust the alignment, if needed.
(5) Remove the exhaust clamp from the exhaust (8) After initial start-up, check the engine exhaust
pipe and catalytic converter connection (Fig. 5) (Fig. manifold to exhaust pipe nuts for proper torque.
6). Disconnect the exhaust pipe from the catalytic
converter. If needed:
EXHAUST PIPE HANGER REAR MOUNTINSULATOR
BRACKET
INSTALLATION
(1) Position the exhaust clamp over the exhaust Fig. 9 Tailpipe Hanger
pipe/catalytic converter connection (Fig. 8). Tighten INSTALLATION
the nuts to 61 N·m (45 ft. lbs.) torque. (1) If the tailpipe hanger assembly was removed,
(2) Install the muffler onto the catalytic converter install the hanger to the frame. Tighten the bolts to
until the alignment tab is inserted into the align- 22 N·m (192 in. lbs.) torque.
ment slot. (2) Position the tailpipe and muffler onto the
(3) Install the exhaust clamp at the muffler and tailpipe hanger (Fig. 9).
catalytic converter connection (Fig. 8). Tighten the (3) Install the muffler onto the catalytic converter.
clamp nuts to 61 N·m (45 ft. lbs.) torque. Make sure that the tailpipe has sufficient clearance
(4) Connect oxygen sensor wiring. from the floor pan. Install exhaust clamp and tighten
(5) Lower the vehicle. the nuts to 61 N·m (45 ft. lbs.) torque.
(6) Start the engine and inspect for exhaust leaks (4) Lower the vehicle.
and exhaust system contact with the body panels. (5) Start the engine and inspect for exhaust leaks
Adjust the alignment, if needed. and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND TAILPIPE
INTAKE AND EXHAUST MANIFOLD—4.0L ENGINE
REMOVAL
All original equipment exhaust systems are manu- REMOVAL
factured with the tailpipe welded to the muffler. Ser-
vice replacement mufflers and tailpipes are either NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
clamped together or welded together. FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
WARNING: IF TORCHES ARE USED WHEN WORK- GASKET AT THE CYLINDER HEAD.
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES. (1) Disconnect the negative cable from the battery.
(2) Remove air cleaner inlet hose from throttle
(1) Raise and support the vehicle. plate assembly.
CYLINDER
33 N·m (24
BOLT
HEAD
ft. lbs.)
TORQUE
DOWEL EXHAUST MANIFOLD
INTAKE MANI-
FOLD
CYLINDER DOWEL
HEAD
23 N·m (17 ft. lbs.)
33 N·m (24 ft. lbs.)
INSPECTION
Inspect mating surfaces of manifold for flatness
with a straight edge. Seal surfaces must be flat
within 0.1 mm (0.004 inch) overall.
SPECIFICATIONS
TORQUE
DESCRIPTION . . . . . . . . . . . . . . . . . . . TORQUE
Adjusting Strap
Bolts . . . . . . . . . . . . . . . . . . . 23 N·m (200 in. lbs.)
Catalytic Converter-to-Exhaust Pipe
U-bolt rod clamp . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Exhaust Pipe-to-Manifold
Nuts . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Exhaust and Intake Manifold–(4.0L)
Bolts#1–5 & #8–11 . . . . . . . . . 33 N·m (24 ft. lbs.)
Exhaust Manifold Heat Shield–(5.2/5.9L)
Nuts . . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft. lbs.)
Exhaust Manifold–(4.0L)
Nuts #6 & 7 . . . . . . . . . . . . . . 31 N·m (23 ft. lbs.)
Exhaust Manifold–(5.2/5.9L)
Nuts/Bolts . . . . . . . . . . . . . . . . 27 N·m (20 ft. lbs.)
Floor Pan Heat Shield
Bolts/Nuts . . . . . . . . . . . . . . . . 5 N·m (45 in. lbs.)
Generator Mounting
Bolts . . . . . . . . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Intake Manifold–(5.2/5.9L)
Bolts . . . . . . . . Refer to Procedure in This Section
Muffler-to-Catalytic Converter
U-bolt rod clamp . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Oxygen Sensor
Sensor . . . . . . . . . . . . . . . . . . . 48 N·m (35 ft. lbs.)
Plenum Pan–(5.2/5.9L)
Bolts . . . . . . . Refer to Procedure in This Section
Rear Tailpipe Hanger
Bolts . . . . . . . . . . . . . . . . . . . 22 N·m (192 in. lbs.)
Throttle Body
Bolts/Nuts . . . . . . . . . . . . . . . 23 N·m (200 in. lbs.)
ZG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
page page
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front muffler clamp from the
exhaust pipe and muffler connection.
(3) Remove the rear exhaust tailpipe hanger clamp
and remove the exhaust tailpipe from the front
exhaust tailpipe hanger.
(4) Remove the exhaust tailpipe assembly from the
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe muffler.
SPECIFICATIONS
TORQUE SPECIFICATIONS
Description Torque
EGR
Attaching Nuts . . . . . . . . . . . . . . . . . . . . . . . 28 N·m
EGR
Tube Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N·m
EGR
Tube Flange Bolts . . . . . . . . . . . . . . . . . . . . . 26 N·m
Exhaust Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m
Exhaust Manifold
Heat Shield Nuts . . . . . . . . . . . . . . . . . . . . . 11 N·m
Exhaust Pipe
Support Clamp Bolts . . . . . . . . . . . . . . . . . 22.5 N·m
Exhaust Pipe
Support Clamp Screw . . . . . . . . . . . . . . . . 22.5 N·m
Intake Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m
Muffler-to-Exhaust Pipe
Clamp Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 43 N·m
Tail Pipe Clamp
Hanger bolt . . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
Turbocharger-to-Exhaust manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m
Turbocharger
Oil Feed Line . . . . . . . . . . . . . . . . . . . . . . . 27.4 N·m
Turbocharger Down Pipe-to-Exhaust Pipe
Bolts/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 N·m
Turbocharger Down Pipe-to-Turbocharger
Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m