Jeep Cherokee 2000 Service Manual - page 1152
CATALYTIC CONVERTER
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.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the clamps from the catalytic converter
and muffler connection (Fig. 9).
(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
becomes cherry red.
(5) While the metal is still cherry red, twist the
muffler assembly back and forth to separate it from
the catalytic converter.
(6) Disconnect the exhaust pipe from the catalytic
converter (Fig. 9). If needed, heat up the pipes to sep-
arate.
INSTALLATION
(1) Connect the catalytic converter to the exhaust
pipe and the muffler/tailpipe assy. (Fig. 9). Use a new
clamp and tighten the nuts to 61 N·m (45 ft. lbs.)
torque.
(2) Install the muffler onto the catalytic converter
until the alignment tab is inserted into the align-
ment slot.
(3) Install a new clamp at the muffler and cata-
lytic converter connection (Fig. 9). Tighten the clamp
nut to 61 N·m (45 ft. lbs.) torque.
(4) Coat the oxygen sensor with anti-seize com-
pound. Install the sensor and tighten the nut to 27
N·m (20 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND 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 LINE.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(1) Raise and support the vehicle.
(2) Disconnect front tailpipe hanger from the insu-
lator (Fig. 10).
(3) Remove the front exhaust clamp from the cat-
alytic converter and muffler connection (Fig. 11).
(4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal
becomes cherry red.
(5) While the metal is still cherry red, remove the
exhaust muffler/tailpipe assembly from the catalytic
converter.
(6) Slide the muffler/tailpipe assy. rearward and
out of the rear exhaust tailpipe mounting bracket
(Fig. 11).
Fig. 9 Catalytic Converter to Muffler and Exhaust
Pipe Connection
1 – EXHAUST CLAMP ASSEMBLY
2 – OXYGEN SENSOR
3 – MUFFLER
4 – CATALYTIC CONVERTER
5 – EXHAUST PIPE
11 - 6
EXHAUST SYSTEM
XJ
REMOVAL AND INSTALLATION (Continued)