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.

Catalytic Converter/Exhaust

Pipe

Exhaust Clamp—Nuts

—

Crossmember to Sill—Bolts

—

Crossmember to Transmission

Mount—Nuts

—

Exhaust Pipe to Manifold—

Nuts Early Build

—

Exhaust Manifold to Engine

2.5L

Engine—

Bolt #1

—

Bolts #2–5

—

Nuts #6&7

—

Exhaust Manifold to Engine

4.0L

Engine—

Nuts #6&7

—

Nuts/Bolts

#1,2,3,4,5,8,9,10&11

—

Muffler to Catalytic

Converter—

Exhaust Clamp Nut Early
Build

—

Exhaust Pipe to Catalytic

Converter

Flange—Nuts Late Build

28.5

—

Muffler to Catalytic Converter

Flange—Nuts

Late Build

28.5

—

Tailpipe to Rear Tailpipe
Hanger—Clamp

Late Build

—

Tailpipe to Rear Tailpipe
Hanger—Clamp

Early Build

—

Oxygen Sensors

—

11 - 12

EXHAUST SYSTEM

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

DESCRIPTION AND OPERATION

EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . . 1

REMOVAL AND INSTALLATION

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MUFFLER AND EXHAUST TAILPIPE. . . . . . . . . . . 2

EXHAUST MANIFOLD AND TURBOCHARGER

(LHD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

EXHAUST MANIFOLD AND TURBOCHARGER

(RHD)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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

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

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

EXHAUST SYSTEM AND TURBOCHARGER

11 - 3

REMOVAL AND INSTALLATION (Continued)

2000 JEEP CHEROKEE

Content .. 327 328 329 330 ..