EXHAUST SYSTEM AND INTAKE MANIFOLD

CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . 3
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . 3
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
EXHAUST MANIFOLD2.5L ENGINE . . . . . . . 8
EXHAUST MANIFOLD4.0L ENGINE . . . . . . . 9
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . 4
INTAKE MANIFOLD2.5L ENGINE . . . . . . . . . 6
INTAKE MANIFOLD4.0L ENGINE . . . . . . . . . 7
MUFFLER AND TAILPIPE ASSEMBLY . . . . . . . 4
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of an engi ne
exhaust mani fol d, exhaust pi pe wi th oxygen sensor,
catal yti c converter wi th oxygen sensor, exhaust heat
shi el d(s), muffl er and exhaust tai l pi pe (Fi g. 1) (Fi g.
2).
The exhaust system uses a si ngl e muffl er wi th a
catal yti c converter consi sti ng of dual cerami c mono-
l i ths.
The 4.0L engi nes use a seal between the engi ne
exhaust mani fol d and exhaust pi pe to assure a ti ght
seal and strai n free connecti ons (Fi g. 2).
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or thei r equi val ent). Thi s wi l l assure
proper al i gnment and provi de acceptabl e exhaust
noi se l evel s.
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.
TJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
Fig. 1 Exhaust System2.5L Engine
Fig. 2 Exhaust System4.0L Engine
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD TJ
GENERAL INFORMATION (Continued)
CATALYTIC CONVERTER
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unl eaded gasol i ne must be used to avoi d contami -
nati ng the catal yst core.
EXHAUST HEAT SHIELDS
Exhaust heat shi el ds are needed to protect both
the vehi cl e and the envi ronment from the hi gh tem-
peratures devel oped by the catal yti c converter. The
catal yti c converter rel eases addi ti onal heat i nto the
exhaust system. Under severe operati ng condi ti ons,
the temperature i ncreases i n the area of the con-
verter. Such condi ti ons can exi st when the engi ne
mi sfi res or otherwi se does not operate at peak effi -
ci ency.
DO NOT remove spark pl ug wi res from pl ugs or by
any other means short out cyl i nders. Fai l ure of the
catal yti c converter can occur due to a temperature
i ncrease caused by unburned fuel passi ng through
the converter.
DO NOT al l ow the engi ne to operate at fast i dl e for
extended peri ods (over 5 mi nutes). Thi s condi ti on
may resul t i n excessi ve temperatures i n the exhaust
system and on the fl oor pan.
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION: When servicing and replacing exhaust
system components, disconnect the oxygen sensor
connector(s). Allowing the exhaust to hang by the
oxygen sensor wires will damage the harness
and/or sensor.
TJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
GENERAL INFORMATION (Continued)
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.
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.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Saturate the studs and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on (Fi g. 3)
(Fi g. 4).
(3) Remove the oxygen sensors from the exhaust
pi pe and the catal yti c converter (Fi g. 3) (Fi g. 4).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal (4.0L engi ne,
onl y) (Fi g. 4).
(5) Support the transmi ssi on and remove the rear
crossmember.
(6) Remove the cl amp from the catal yti c converter
and muffl er connecti on.
(7) Heat the catal yti c converter and muffl er con-
necti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(8) Whi l e the metal i s sti l l cherry red, twi st the
muffl er assembl y back and forth to separate i t from
the catal yti c converter.
INSTALLATION
(1) Assembl e catal yti c converter and muffl er
l oosel y to permi t proper al i gnment of al l parts.
(2) Use a new cl amp and ti ghten the nut to 48
Nm (35 ft. l bs.) torque.
(3) Connect the exhaust pi pe to the engi ne exhaust
mani fol d. I nstal l a new seal between the exhaust
mani fol d and the exhaust pi pe (4.0L engi ne, onl y).
Ti ghten the nuts to 31 Nm (23 ft. l bs.) torque.
(4) I nstal l the rear crossmember. Ti ghten the
crossmember-to-si l l bol ts to 41 Nm (30 ft. l bs.)
torque. Remove the support from the transmi ssi on.
(5) Coat the oxygen sensors wi th anti -sei ze com-
pound. I nstal l the sensors and ti ghten the nut to 48
Nm (35 ft. l bs.) torque.
(6) Lower the vehi cl e.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
MUFFLER AND TAILPIPE ASSEMBLY
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
Fig. 3 Exhaust Pipe with Catalytic Converter2.5 L
Engine
Fig. 4 Exhaust Pipe with Catalytic Converter4.0 L
Engine
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD TJ
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.
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
REMOVAL
(1) Rai se the vehi cl e and support the rear of the
vehi cl e by the si de rai l s and al l ow the axl e to hang
free.
(2) Remove the cl amp from the catal yti c converter
and muffl er connecti on (Fi g. 5).
(3) Remove the tai l pi pe hangers from the i nsul a-
tors (Fi g. 6).
(4) Heat the catal yti c converter-to-muffl er connec-
ti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, twi st the
exhaust tai l pi pe/muffl er assembl y back and forth to
separate i t from the catal yti c converter.
To separate an ori gi nal equi pment exhaust
tai l pi pe/muffl er combi nati on, cut the exhaust tai l pi pe
cl ose to the muffl er. Col l apse the part remai ni ng i n
the muffl er and remove.
To remove a servi ce exhaust tai l pi pe/muffl er
combi nati on, appl y heat unti l the metal becomes
cherry red. Remove the exhaust tai l pi pe/muffl er
cl amp and twi st the exhaust tai l pi pe out of the muf-
fl er.
INSTALLATION
(1) Assembl e catal yti c converter and muffl er
l oosel y to permi t proper al i gnment of al l parts.
Fig. 6 Muffler and Tailpipe Assembly
Fig. 5 Catalytic Converter to Muffler Connection
TJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe hanger. Make sure that
the exhaust tai l pi pe has suffi ci ent cl earance from the
fl oor pan.
(4) Ti ghten the nut on the muffl er-to-catal yti c con-
verter cl amp to 48 Nm (35 ft. l bs.) torque.
(5) I nsert rods i nto i sol ators.
(6) Lower the vehi cl e.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
INTAKE MANIFOLD2. 5L ENGINE
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove the ai r i nl et hose and resonator from
the throttl e body and ai r cl eaner housi ng (Fi g. 7).
(3) Loosen the accessory dri ve bel t tensi on and
remove the bel t from the power steeri ng pump.
(Refer to Group 7, Cool i ng for correct procedure).
(4) Remove the power steeri ng pump and brackets
from the water pump and i ntake mani fol d. Support
power steeri ng pump and bracket wi th mechani cs
wi re attached to the radi ator upper crossmember.
(5) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel System for correct proce-
dure)
(6) Di sconnect fuel suppl y tube from the fuel rai l .
(Refer to Group 14, Fuel System - Qui ck Connect Fi t-
ti ngs)
(7) Di sconnect the accel erator cabl e from the throt-
tl e body and cabl e bracket.
(8) Di sconnect the speed control and transmi ssi on
l i ne pressure cabl e from the throttl e body and cabl e
bracket (i f equi pped).
CAUTION: When disconnecting the speed control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(9) Di sconnect the el ectri cal connectors. Pul l the
harnesses away from the mani fol d.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat housi ng.
The mani fol d ai r temperature sensor at the
i ntake mani fol d.
The fuel i njectors.
The oxygen sensor.
(10) Di sconnect the crankcase venti l ati on (CCV)
vacuum hose and mani fol d absol ute pressure (MAP)
sensor vacuum hose connector at the i ntake mani -
fol d.
(11) Di sconnect HVAC suppl y vacuum hose from
i ntake mani fol d.
(12) Di sconnect CCV hose at the cyl i nder head
cover (Fi g. 7).
(13) Remove the mol ded vacuum harness.
(14) Di sconnect the vacuum brake booster hose at
the i ntake mani fol d.
(15) Remove bol ts 2 through 5 securi ng the i ntake
mani fol d to the cyl i nder head (Fi g. 8). LOOSEN BUT
DO NOT REMOVE exhaust mani fol d bol t No. 1 and
nuts 6 and 7.
(16) Remove the i ntake mani fol d and gaskets.
Drai n the cool ant from the mani fol d.
Fig. 7 Air Inlet/CCV System2.5L Engine
Fig. 8 Intake/Exhaust Manifold2.5L Engine
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD TJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Cl ean the i ntake mani fol d and cyl i nder head
mati ng surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) I nstal l the new i ntake mani fol d gasket over the
l ocati ng dowel s.
(3) Posi ti on the mani fol d i n pl ace and fi nger
ti ghten the mounti ng bol ts.
(4) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 8).
Fastener No. 1Ti ghten to 41 Nm (30 ft. l bs.)
torque.
Fasteners Nos. 2 through 7Ti ghten to 31 Nm
(23 ft. l bs.) torque.
(5) Before connecting the fuel line to the fuel
rail inspect the fuel line O-rings and replace
them if necessary. Connect the fuel suppl y tube to
the fuel rai l i nl et. Push tube unti l a cl i ck i s heard.
(6) Pul l out on fuel suppl y l i ne to veri fy that i t i s
properl y connected. I nstal l l atch cl i p.
(7) Connect the mol ded vacuum hoses to the vac-
uum port on the i ntake mani fol d and the cyl i nder
head cover.
(8) Connect the el ectri cal connectors.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat housi ng.
The mani fol d ai r temperature sensor at the
i ntake mani fol d.
The fuel i njectors.
The oxygen sensor.
(9) Connect the brake booster vacuum suppl y hose.
(10) Connect the CCV hose and MAP sensor vac-
uum hose connectors to the throttl e body.
(11) I nstal l the power steeri ng pump and bracket
assembl y to the water pump and i ntake mani fol d.
Torque power steeri ng pump bol ts to 28 Nm (21 ft.
l bs.). Torque bracket to water pump bol ts to 47 Nm
(35 ft. l bs.).
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(12) I nstal l and tensi on the accessory dri ve bel t.
(Refer to Group 7, Cool i ng System for the correct pro-
cedure)
(13) Connect the accel erator cabl e to the bracket
and the throttl e l ever.
(14) Connect the speed control and transmi ssi on
l i ne pressure cabl e (i f equi pped) to the bracket and
throttl e l ever.
(15) I nstal l the ai r i nl et hose and resonator to the
throttl e body and the ai r cl eaner.
(16) Connect the battery negati ve cabl e.
(17) Start the engi ne and check for l eaks.
INTAKE MANIFOLD4. 0L ENGINE
The i ntake and engi ne exhaust mani fol ds on the
4.0L engi ne must be removed and i nstal l ed together.
The two mani fol ds use a common gasket at the cyl -
i nder head.
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove ai r cl eaner i nl et hose from the throttl e
body and ai r cl eaner assy (Fi g. 9).
(3) Di sconnect the accel erator cabl e, speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e (i f equi pped). Remove these cabl es from
the bracket.
(4) Di sconnect the fol l owi ng el ectri cal connectors:
Map Sensor
I dl e Ai r Control Motor
I ntake Mani fol d Ai r Temperature Sensor
Throttl e Posi ti on Sensor
Oxygen Sensor Connector
Fuel I njector Connectors
(5) Secure the el ectri cal harness out of the way.
(6) Di sconnect the power brake booster vacuum
suppl y hose from the i ntake mani fol d.
(7) Di sconnect the CCV hose from the i ntake man-
i fol d.
(8) Di sconnect the HVAC vacuum suppl y hose from
the i ntake mani fol d.
(9) Di sconnect cani ster purge vacuum suppl y form
the i ntake mani fol d.
(10) Perform the fuel pressure rel ease procedure
(Refer to Group 14, Fuel System for correct proce-
dure).
(11) Di sconnect fuel suppl y l i ne from the fuel rai l
assembl y (Refer to Group 14, Fuel System for correct
procedure).
(12) Loosen the accessory dri ve bel t (Refer to
Group 7, Cool i ng System). Sl i p the bel t off of the
power steeri ng pul l ey.
(13) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump and set
asi de.
(14) Rai se vehi cl e on hoi st.
(15) Di sconnect the exhaust pi pe from the exhaust
mani fol d. Di scard the seal .
(16) Lower the vehi cl e.
TJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)
(17) Remove the i ntake mani fol d and exhaust
mani fol d.
INSTALLATION
(1) Cl ean the mati ng surfaces of the cyl i nder head
and the mani fol d(s). I f the mani fol d i s bei ng
repl aced, ensure that al l the fi tti ngs, etc. are trans-
ferred to the repl acement mani fol d.
(2) I nstal l a new exhaust/i ntake mani fol d gasket
over the al i gnment dowel s on the cyl i nder head.
(3) Posi ti on the engi ne exhaust mani fol d to the
cyl i nder head. I nstal l fastener No.3 and fi nger
ti ghten at thi s ti me (Fi g. 10).
(4) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(5) I nstal l washers and fasteners Nos. 1, 2, 4, 5, 8,
9, 10 and 11 (Fi g. 10).
(6) I nstal l washers and fasteners Nos. 6 and 7
(Fi g. 10).
(7) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 10).
Fasteners Nos. 1 through 5Ti ghten to 33 Nm
(24 ft. l bs.) torque.
Fasteners Nos. 6 and 7Ti ghten to 31 Nm (23
ft. l bs.) torque.
Fasteners Nos. 8 through 11Ti ghten to 33 Nm
(24 ft. l bs.) torque.
(8) I nstal l the power steeri ng pump and bracket to
the i ntake mani fol d and water pump. Torque the
power steeri ng pump/bracket to mani fol d bol ts to 28
Nm (21 ft. l bs.). Torque the power steeri ng pump
bracket to water pump bol ts to 47 Nm (35 ft. l bs.).
(9) I nstal l accessory dri ve bel t and ti ghten to spec-
i fi cati on. (Refer to group 7, Cool i ng for correct proce-
dure).
(10) Before connecting the fuel line to the
fuel rail, inspect the fuel line O-rings and
replace them if necessary. Connect the fuel suppl y
l i ne to the fuel rai l assembl y. (Refer to Group 14,
Fuel System for the correct procedure).
(11) Connect al l sensor el ectri cal connecti ons on
the i ntake mani fol d.
Map Sensor
I dl e Ai r Control Motor
I ntake Mani fol d Ai r Temperature Sensor
Throttl e Posi ti on Sensor
Oxygen Sensor Connector
Fuel I njector Connectors
(12) Connect the power brake booster and HVAC
vacuum suppl y hoses.
(13) Connect the cani ster purge vacuum suppl y
hose to the mani fol d.
(14) I nstal l the throttl e cabl e, crui se control cabl e
(i f equi pped), and transmi ssi on l i ne pressure (i f
equi pped) cabl es i nto the bracket. Connect the cabl es
to the throttl e body.
(15) Connect ai r i nl et hose to the throttl e body and
ai r cl eaner housi ng.
(16) Rai se vehi cl e on hoi st.
(17) Usi ng a new seal , connect the exhaust pi pe to
the engi ne exhaust mani fol d. Ti ghten the bol ts to 31
Nm (23 ft. l bs.) torque.
(18) Lower the vehi cl e.
(19) Connect the battery negati ve cabl e.
(20) Start the engi ne and check for l eaks.
EXHAUST MANIFOLD2. 5L ENGINE
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Rai se the vehi cl e.
Fig. 9 Air Inlet/CCV System4.0L Engine
Fig. 10 Intake/Engine Exhaust Manifold
Installation4.0L Engine
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD TJ
REMOVAL AND INSTALLATION (Continued)
(3) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d.
(4) Lower the vehi cl e.
(5) Remove the i ntake mani fol d. (Refer to proce-
dure i n thi s secti on).
(6) Remove fasteners 2 through 5 and remove the
i ntake mani fol d (Fi g. 11).
(7) Remove fasteners 1, 6 and 7 and remove the
engi ne exhaust mani fol d (Fi g. 11).
INSTALLATION
(1) Cl ean the i ntake and engi ne exhaust mani fol ds
and cyl i nder head mati ng surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) I nstal l a new i ntake mani fol d gasket over the
al i gnment dowel s on the cyl i nder head.
(3) I nstal l the engi ne exhaust mani fol d assembl y.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 11).
(4) Ti ghten bol t No. 1 to 41 Nm (30 ft. l bs.) torque
(Fi g. 11).
(5) I nstal l the i ntake mani fol d on the cyl i nder
head dowel s (Fi g. 11).
(6) I nstal l bol ts 2 through 5 (Fi g. 11). Ti ghten
these bol ts to 31 Nm (23 ft. l bs.) torque.
(7) I nstal l new engi ne exhaust mani fol d spacers
over the engi ne exhaust mani fol d mounti ng studs i n
the cyl i nder head (Fi g. 11).
(8) Ti ghten nuts 6 and 7 to 31 Nm (23 ft. l bs.)
torque (Fi g. 11).
(9) I nstal l al l components to the i ntake mani fol d.
(10) Rai se the vehi cl e.
(11) Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the bol ts to 31 Nm (23 ft.
l bs.) torque.
(12) Lower the vehi cl e.
(13) Connect the battery negati ve cabl e.
(14) Start the engi ne and check for l eaks.
EXHAUST MANIFOLD4. 0L ENGINE
The i ntake and engi ne exhaust mani fol ds on the
4.0L engi ne must be removed and i nstal l ed together.
The mani fol ds use a common gasket at the cyl i nder
head.
Refer to I ntake Mani fol d4.0L Engi ne i n thi s sec-
ti on for the proper removal and i nstal l ati on proce-
dures.
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Crossmember to Sill
Bol ts . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Exhaust Pipe to Manifold
Nuts . . . . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Intake/Exhaust Manifold
2.5L Engine
Exhaust Mani fol d Bol t #1 . . . . 41 Nm (30 ft. l bs.)
I ntake/Exhaust Mani fol d
Bol ts #25 . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Exhaust Mani fol d Nuts #6&7 . . . 31 Nm (23 ft. l bs.)
Intake/Exhaust Manifold
4.0L Engine
I ntake/Exhaust Mani fol d
Nuts/Bol ts #1,2,4,5,811 . . . . . 33 Nm (24 ft. l bs.)
Exhaust Mani fol d Bol t #3 . . . . 33 Nm (24 ft. l bs.)
Exhaust Mani fol d Nuts #6&7 . . . 31 Nm (23 ft. l bs.)
Muffler to Catalytic Converter
Cl amp Nut . . . . . . . . . . . . . . . 48 Nm (35 ft. l bs.)
Oxygen Sensors
Nut . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
Power Steering Pump/
Tensioner Bracket
Bol ts (to i ntake) . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Bol ts (to water pump) . . . . . . . 48 Nm (35 ft. l bs.)
Fig. 11 Intake/Engine Exhaust Manifold
Installation2.5L Engine
TJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)