Jeep Wrangler TJ. Manual — part 456
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
t
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. 6).
(5) Remove catalytic converter to muffler flange
retaining nuts (Fig. 6).
(6) Slide exhaust pipe foward until exhaust pipe
hanger
disengages
from
transmission
support.
Remove exhaust pipe and catalytic converter from
vehicle.
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.
(9) Lower vehicle.
(10) Start engine and inspect for leaks. Repair
exhaust leaks as necessary.
(11) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
Fig. 5 Exhaust Pipe and Calalytic Converter - 2.4L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
Fig. 6 Exhaust Pipe and Catalytic Converter - 4.0L
1 - CATALYTIC CONVERTER
2 - TRANSMISSION SUPPORT
3 - EXHAUST HANGER
4 - EXHAUST PIPE
TJ
EXHAUST SYSTEM
11 - 7
EXHAUST PIPE (Continued)
INSTALLATION - 4.0L
(1) Position exhaust pipe and catalytic converter
into vehicle.
(2) Insert exhaust pipe hanger into transmission
support (Fig. 6).
(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. 6).
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.
(9) Lower vehicle.
(10) Start engine and inspect for leaks. Repair
exhaust leaks as necessary.
(11) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
HEAT SHIELDS
DESCRIPTION
Heat shields (Fig. 7) are made of stamped/formed
steel, or metal foil.
Exhaust heat shields are needed to protect both the
vehicle and the environment from the high tempera-
tures developed by the catalytic converter. The cata-
lytic converter releases additional heat into the
exhaust system. Under severe operating conditions,
the temperature increases in the area of the converter.
Such conditions can exist when the engine misfires or
otherwise does not operate at peak efficiency.
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. 8)
and (Fig. 9).
(3) When removing muffler heat shield, the muf-
fler front support bracket must be removed first.
(4) Slide the shields out around the exhaust system.
INSTALLATION
(1)
Position the heat shields to the floor pan or
the frame and install the screws and/or nuts (Fig. 8)
and (Fig. 9).
(2) Tighten the nuts and/or screws to 45 N·m (33
ft. lbs.).
(3) Lower the vehicle.
Fig. 7 Exhaust Heat Shield - Typical
1 - HEAT SHIELD
Fig. 8 Muffler Heat Shield - Rear
1 - MUFFLER HEAT SHIELD - REAR
2 - NUTS
3 - SELF TAPPING SCREWS
Fig. 9 Muffler Heat Shield - Middle
1 - MUFFLER HEAT SHIELD - MIDDLE
2 - NUTS
3 - SELF TAPPING SCREWS
11 - 8
EXHAUST SYSTEM
TJ
EXHAUST PIPE (Continued)
MUFFLER
DESCRIPTION
Both the 2.4L and 4.0L engines use a galvanized
steel muffler (Fig. 10) to control exhaust noise levels
and exhaust back pressure.
REMOVAL
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.
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.
(1) Raise the vehicle and support the rear of the
vehicle by the side rails and allow the axle to hang
free.
(2) Remove the tailpipe hangers from the insula-
tors (Fig. 11).
(3) Remove muffler to catalytic converter flange
retaining nuts (Fig. 11).
(4) Remove muffler and tailpipe assembly from
vehicle.
Fig. 10 Muffler
1 - MUFFLER
TJ
EXHAUST SYSTEM
11 - 9
INSTALLATION
(1) Position muffler and tailpipe assembly into
vehicle.
(2) Position muffler and catalytic converter flanges
together and install nuts (Fig. 11). DO NOT tighten
nuts at this time.
(3) Install tailpipe hangers into the insulators (Fig.
11).
(4) Make sure the muffler and tailpipe are cor-
rectly positioned and the proper alignment. The min-
imum clearance between components is 25mm (1
inch).
(5) Tighten muffler to catalytic converter flange
nuts to 28.5 N·m (21 ft. lbs.).
(6) Lower vehicle.
(7) Start engine and inspect for leaks. Repair
exhaust leaks as necessary.
(8) Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.
Fig. 11 Muffler and Tailpipe
1 - TRANSMISSION SUPPORT
2 - TAILPIPE HANGER INSULATORS
3 - TAILPIPE HANGERS
4 - TAILPIPE
5 - MUFFLER
6 - MUFFLER TO CATALYTIC CONVERTER FLANGE
7 - NUTS
8 - CATALYTIC CONVERTER
11 - 10
EXHAUST SYSTEM
TJ
MUFFLER (Continued)
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