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CAUTION: When servicing exhaust system compo- REMOVAL (1) Raise and support the vehicle. and muffler connection (Fig. 14). (3) Disconnect and remove the oxygen sensor from the catalytic converter. (4) Heat the catalytic converter and muffler con- nection with an oxyacetylene torch until the metal (5) While the metal is still cherry red, twist the muffler assembly back and forth to separate it from (6) Disconnect the exhaust pipe from the catalytic converter (Fig. 14). If needed, heat up the pipes to INSTALLATION (1) Connect the catalytic converter to the exhaust pipe and the muffler/tailpipe assy. (Fig. 14). Use a (2) Install the muffler onto the catalytic converter until the alignment tab is inserted into the align- (3) Install a new clamp at the muffler and cata- lytic converter connection (Fig. 14). Tighten the (4) Coat the oxygen sensor with anti-seize com- pound. Install the sensor and tighten the nut to 27 (5) Lower the vehicle. and exhaust system contact with the body panels. CATALYTIC CONVERTER—LATE BUILD WARNING: IF TORCHES ARE USED WHEN WORK- CAUTION: When servicing exhaust system compo- REMOVAL (1) Raise and support the vehicle. the catalytic converter. (3) Saturate the bolts and nuts with Mopar t Rust Penetrant. Allow 5 minutes for penetration. (4) Remove the nuts and bolts then disconnect the catalytic converter flange from the muffler flange. (5) Remove the nuts from the catalytic converter to exhaust pipe flange and remove catalytic converter INSTALLATION (1) Position a new gasket then position catalytic converter onto exhaust pipe (Fig. 15), install three (2) Position muffler flange onto catalytic converter flange and install nuts and bolts. Tighten Nuts to Fig. 14 Catalytic Converter to Muffler and Exhaust Pipe Connection—Early Build 1 – EXHAUST CLAMP ASSEMBLY 11 - 8 EXHAUST SYSTEM XJ REMOVAL AND INSTALLATION (Continued) 2000 XJ Service Manual March, 2000 |