Jeep XJ. Manual — part 329
(4) Make sure the exhaust system is in proper
alignment. There should be at least 25mm (1 inch)
clearance between the exhaust components and any
surrounding components.
(5) Tighten muffler to catalytic converter flange
mounting nuts to 28.5 N·m (21 ft. lbs.).
(6) Tighten tailpipe clamp to 48 N·m (35 ft. lbs.).
HEAT SHIELDS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the screws and/or nuts holding the
heat shields to the frame and/or floor pan (Fig. 19).
(3) When removing muffler heat shield, the muf-
fler front support bracket must be removed first.
(4) Slide the shields out around the exhaust sys-
tem.
INSTALLATION
(1) Position the heat shields to the floor pan or the
frame and install the screws and/or nuts.
(2) Tighten the nuts and/or screws to 45 N·m (33
ft. lbs.) (Fig. 19).
(3) Lower the vehicle.
SPECIFICATIONS
TORQUE SPECIFICATIONS
Fig. 19 Heat Shield Removal/Installation
1 – BOLTS
2 – MUFFLER HEAT SHIELD
3 – NUTS
4 – FLOOR PAN
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Catalytic Converter/Exhaust
Pipe
Exhaust Clamp—Nuts
61
45
—
Crossmember to Sill—Bolts
42
31
—
Crossmember to Transmission
Mount—Nuts
22
16
—
Exhaust Pipe to Manifold—
Nuts Early Build
31
23
—
Exhaust Manifold to Engine
2.5L
Engine—
Bolt #1
41
40
—
Bolts #2–5
31
23
—
Nuts #6&7
31
23
—
Exhaust Manifold to Engine
4.0L
Engine—
Nuts #6&7
31
23
—
Nuts/Bolts
#1,2,3,4,5,8,9,10&11
33
24
—
Muffler to Catalytic
Converter—
Exhaust Clamp Nut Early
Build
61
45
—
Exhaust Pipe to Catalytic
Converter
Flange—Nuts Late Build
28.5
21
—
Muffler to Catalytic Converter
Flange—Nuts
Late Build
28.5
21
—
Tailpipe to Rear Tailpipe
Hanger—Clamp
Late Build
48
35
—
Tailpipe to Rear Tailpipe
Hanger—Clamp
Early Build
27
20
—
Oxygen Sensors
27
20
—
11 - 12
EXHAUST SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)
2000 XJ Service Manual
Publication No. 81-370-0046
TSB 26-03-00
March, 2000
EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
REMOVAL AND INSTALLATION
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MUFFLER AND EXHAUST TAILPIPE. . . . . . . . . . . 2
EXHAUST MANIFOLD AND TURBOCHARGER
(LHD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXHAUST MANIFOLD AND TURBOCHARGER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTAKE MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 10
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
The basic exhaust system consists of an engine
exhaust manifold, turbocharger,exhaust down pipe,
exhaust pipe, exhaust heat shield(s), muffler and
exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken hangers. Replace all components that are
badly corroded or damaged. DO NOT attempt to
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
CAUTION: Avoid
application
of
rust
prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over-
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both
the vehicle and the environment from the high tem-
peratures (Fig. 1).
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.
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.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts at turbo down pipe
to exhaust pipe with heat valve lubricant. Allow 5
minutes for penetration..
(3) Disconnect bolts from exhaust pipe to turbo
down pipe (Fig. 2).
Fig. 1 Heat Shields
1 – EXHAUST MANIFOLD HEAT SHIELD
2 – DOWN PIPE HEAT SHIELD
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 1
2000 JEEP CHEROKEE
(4) Remove the clamp nuts at muffler (Fig. 3). To
remove the exhaust pipe from the muffler, apply heat
until the metal becomes cherry red. Disconnect the
exhaust pipe from the muffler. Remove the exhaust
pipe.
INSTALLATION
(1) Assemble exhaust pipe to muffler, loosely to
permit proper alignment of all parts.
(2) Connect the exhaust pipe to the turbo down
pipe manifold. Tighten the bolts to 22.5 N·m torque.
(3) Use a new clamp and tighten the nuts to 43
N·m torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST TAILPIPE
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler.
Service
replacement
mufflers
and
exhaust
tailpipes are either clamped together or welded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
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
muffler.
INSTALLATION
(1) Install the muffler onto the exhaust pipe.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe hanger. Make sure that
the exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front
exhaust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-exhaust pipe
clamp to 43 N·m 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 MANIFOLD AND TURBOCHARGER
(LHD)
REMOVAL
(1) Disconnect the negative battery cable
(2) Disconnect the breather hose from air cleaner
outlet hose (Fig. 4).
Fig. 2 Exhaust Down Pipe to Exhaust Pipe
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
Fig. 3 Front Pipe to Muffler
1 – BRACKET
2 – FRONT PIPE
3 – RUBBER ISOLATOR
4 – MUFFLER
11 - 2
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
(3) Remove the air filter cover and hose from tur-
bocharger, remove the assembly (Fig. 4).
(4) Remove the EGR vacuum supply hose from the
EGR valve.
(5) Remove the innercooler inlet and outlet hoses
from the engine (Fig. 4).
(6) Remove the (2) bolts holding the EGR tube to
the EGR valve.
(7) Remove the intake manifold elbow and EGR
valve as an assembly.
(8) Raise the vehicle on a hoist.
(9) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(10) Remove the exhaust system support clamp
(Fig. 5).
(11) Disconnect the exhaust system at the (3) bolt
flange (Fig. 5).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(12) Unstrap the exhaust downpipe heatshield
(Fig. 6).
(13) Disconnect the turbocharger oil return hose
from the engine block (Fig. 7).
(14) Lower the vehicle from the hoist.
(15) Remove the EGR tube from exhaust manifold.
(16) Remove the (2) exhaust manifold heatshield
retaining bolts and remove the heatshield.
(17) Remove the heater supply and return hoses
from the vehicle.
(18) Remove the oil pressure supply line bango
bolt from the turbocharger.
Fig. 4 Engine Compartment
1 – INTAKE MANIFOLD ELBOW
2 – BREATHER HOSE
3 – INNERCOOLER OUTLET HOSE
4 – AIR FILTER COVER
5 – AIR FILTER OUTLET (FRESH AIR) HOSE
6 – INNERCOOLER INLET HOSE
7 – HEATER CORE COOLANT SUPPLY HOSES
Fig. 5 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
Fig. 6 Exhaust Downpipe Heatshield
1 – EXHAUST MANIFOLD DOWNPIPE HEATSHIELD RETAINING
STRAPS
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 3
REMOVAL AND INSTALLATION (Continued)
2000 JEEP CHEROKEE
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