EXHAUST SYSTEM AND INTAKE MANIFOLD

CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 4
EXHAUST MANIFOLD5.2/5.9L ENGINE . . . . . 8
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTAKE AND EXHAUST MANIFOLD
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTAKE MANIFOLD5.2/5.9L ENGINE . . . . . . . 6
MUFFLER AND TAILPIPE . . . . . . . . . . . . . . . . . . 5
CLEANING AND INSPECTION
EXHAUST MANIFOLD5.2/5.9L ENGINE . . . . . 9
INTAKE AND EXHAUST MANIFOLD
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD 5.2/5.9L ENGINE . . . . . . . 9
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensor, catal yti c
converter, heat shi el d(s), muffl er and tai l pi pe (Fi g. 1)
(Fi g. 2).
The exhaust system uses a si ngl e muffl er wi th a
si ngl e monol i thi c-type catal yti c converter.
The 4.0L engi nes use a seal between the exhaust
mani fol d and exhaust pi pe to assure a ti ght seal and
strai n free connecti ons.
The 5.2L/5.9L exhaust mani fol ds are equi pped wi th
bal l fl ange outl ets to assure a ti ght seal and strai n
free connecti ons.
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
Fig. 2 Exhaust System5.2L/5.9L
Fig. 1 Exhaust System4.0L
ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1
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 heat shields. Light over spray
near the edges is permitted. Application of coating
will result in excessive floor pan temperatures and
objectionable fumes.
CATALYTIC CONVERTER
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the 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.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
HEAT SHIELDS
Heat shi el ds are needed to protect both the vehi cl e
and the envi ronment from the hi gh temperatures
devel oped by the catal yti c converter (Fi g. 3) (Fi g. 4).
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
converter. 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.
Fig. 3 Front Floor Pan Heat Shield
Fig. 4 Rear Floor Pan Heat Shield
11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD ZJ
GENERAL INFORMATION (Continued)
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
REMOVAL AND INSTALLATION
EXHAUST PIPE
REMOVAL
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 sensor and/or wiring.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the oxygen sensor from the exhaust
pi pe (Fi g. 5) (Fi g. 6).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. On 4.0L engi nes, di scard the
exhaust mani fol d seal (Fi g. 5).
(5) Remove the exhaust cl amp from the exhaust
pi pe and catal yti c converter connecti on (Fi g. 5) (Fi g.
6). Di sconnect the exhaust pi pe from the catal yti c
converter. I f needed:
(a) Heat the exhaust pi pe and catal yti c con-
verter connecti on wi th an torch unti l the metal
becomes cherry red.
(b) Whi l e the metal i s sti l l cherry red, twi st the
exhaust pi pe back and forth to separate i t from the
catal yti c converter.
(6) Di sconnect the exhaust pi pe hanger from the
rear mount bracket i nsul ator.
(7) Remove the exhaust pi pe.
INSTALLATION
(1) Posi ti on the exhaust pi pe onto the catal yti c
converter.
(2) Connect the exhaust pi pe hanger to the rear
mount bracket i nsul ator.
(3) On 4.0L engi nes, i nstal l a new seal between
the exhaust pi pe and the engi ne exhaust mani fol d
(Fi g. 5). Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the nuts to 31 Nm (23 ft.
l bs.) torque.
(4) Posi ti on the exhaust cl amp over the exhaust
pi pe/catal yti c converter connecti on (Fi g. 5) (Fi g. 6).
Ti ghten the nuts to 48 Nm (35 ft. l bs.) torque.
(5) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 30
Nm (22 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.
(8) After i ni ti al start-up, check the exhaust mani -
fol d to pi pe nuts for proper torque.
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST
NOISE
1. Leaks at pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or blown out muffler. 2. Replace muffler assembly. Check
exhaust system.
3. Burned or rusted-out exhaust pipe. 3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten connection attaching nuts.
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 stud nuts or bolts.
7. Restriction in muffler or tailpipe. 7. Remove restriction, if possible. Replace
muffler or tailpipe, as necessary.
8. Exhaust system contacting body or
chassis.
8. Re-align exhaust system to clear
surrounding components.
LEAKING EXHAUST
GASES
1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints.
2. Damaged or improperly installed
gaskets.
2. Replace gaskets as necessary
ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3
CATALYTIC CONVERTER
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove exhaust cl amp from the catal yti c con-
verter and exhaust pi pe connecti on (Fi g. 7).
(4) Remove exhaust cl amp from the catal yti c con-
verter and muffl er connecti on (Fi g. 7).
(5) Di sconnect oxygen sensor wi ri ng.
(6) Heat the exhaust pi pe, catal yti c converter and
muffl er connecti ons wi th an torch unti l the metal
becomes cherry red.
Fig. 5 Exhaust System4.0L Engine
Fig. 6 Exhaust Pipe5.2L/5.9L Engines
Fig. 7 Exhaust Pipe-to-Catalytic Converter-to-Muffler
Connection
11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD ZJ
REMOVAL AND INSTALLATION (Continued)
(7) Whi l e the metal i s sti l l cherry red, twi st the
catal yti c converter back and forth to separate i t from
the exhaust pi pe and the muffl er.
INSTALLATION
(1) Posi ti on the exhaust cl amp over the exhaust
pi pe/catal yti c converter connecti on (Fi g. 7). Ti ghten
the nuts to 61 Nm (45 ft. l bs.) torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l the exhaust cl amp at the muffl er and
catal yti c converter connecti on (Fi g. 7). Ti ghten the
cl amp nuts to 61 Nm (45 ft. l bs.) torque.
(4) Connect oxygen sensor wi ri ng.
(5) Lower the vehi cl e.
(6) 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
REMOVAL
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the tai l pi pe wel ded to the muffl er. Ser-
vi ce repl acement muffl ers and tai l pi pes are ei ther
cl amped together or wel ded together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant. Al l ow 5 mi nutes for penetrati on.
(3) Remove the exhaust cl amp from the catal yti c
converter and muffl er connecti on (Fi g. 7).
(4) Heat the catal yti c converter-to-muffl er connecti on
wi th an torch unti l the metal becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, remove the
tai l pi pe/muffl er assembl y from the catal yti c con-
verter.
(6) Remove the tai l pi pe from the tai l pi pe hanger
(Fi g. 8).
(7) Remove the tai l pi pe/muffl er assembl y.
INSTALLATION
(1) I f the tai l pi pe hanger assembl y was removed,
i nstal l the hanger to the frame. Ti ghten the bol ts to
22 Nm (192 i n. l bs.) torque.
(2) Posi ti on the tai l pi pe and muffl er onto the
tai l pi pe hanger (Fi g. 8).
(3) I nstal l the muffl er onto the catal yti c converter.
Make sure that the tai l pi pe has suffi ci ent cl earance
from the fl oor pan. I nstal l exhaust cl amp and ti ghten
the nuts to 61 Nm (45 ft. l bs.) torque.
(4) Lower the vehi cl e.
(5) 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 AND EXHAUST MANIFOLD4. 0L ENGINE
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(1) Di sconnect the battery negati ve cabl e.
(2) Remove ai r cl eaner i nl et hose from throttl e
body assembl y.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e.
(5) Di sconnect the fol l owi ng el ectri cal connecti ons
and secure thei r harness out of the way:
Throttl e Posi ti on Sensor
I dl e Ai r Control Motor
Cool ant Temperature Sensor (at thermostat
housi ng)
I ntake Ai r Temperature Sensor
Oxygen Sensor
Crank Posi ti on Sensor
Si x (6) Fuel I njector Connectors
(6) Di sconnect the Map Sensor, HVAC, and Brake
Booster vacuum suppl y hoses at the i ntake mani fol d.
(7) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel Systems for correct procedure)
(8) Di sconnect and remove the fuel system suppl y
l i ne from the fuel rai l assembl y. (Refer to Group 14,
Qui ck Connect Fi tti ngs for correct procedures)
(9) Loosen the accessory dri ve bel t (refer to Group
7, Cool i ng System). Loosen the tensi oner.
(10) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and set asi de.
Fig. 8 Tailpipe Hanger
ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5
REMOVAL AND INSTALLATION (Continued)
(11) Rai se the vehi cl e.
(12) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal .
(13) Lower the vehi cl e.
(14) Remove the i ntake mani fol d and engi ne
exhaust mani fol d.
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol d to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 9).
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 9).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 9).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 9).
Fastener Numbers 1 through 5Ti ghten to 33
Nm (24 ft. l bs.) torque.
Fastener Numbers 6 and 7Ti ghten to 31 Nm
(23 ft. l bs.) torque.
Fastener Numbers 8 through 11Ti ghten to 33
Nm (24 ft. l bs.) torque.
(7) I nstal l the power steeri ng pump and bracket to
the i ntake mani fol d. Ti ghten the bel t to speci fi cati on.
(Refer to Group 7, Cool i ng System for the correct pro-
cedures)
(8) I nstal l the fuel system suppl y l i ne to the fuel
rai l assembl y. Before connecting the fuel supply
line to the fuel rail inspect the O-rings and
replace if necessary. Refer to Group 14, Fuel
System for the correct procedure.
(9) Connect al l el ectri cal connecti ons on the i ntake
mani fol d.
(10) Connect the vacuum hoses previ ousl y
removed.
(11) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(12) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped). Refer to Group 21, Transmi ssi on for the
adjustment procedures.
(13) I nstal l ai r cl eaner assembl y.
(14) Connect ai r i nl et hose to the throttl e body
assembl y.
(15) Rai se the vehi cl e.
(16) Usi ng a new exhaust mani fol d 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.)
(17) Lower the vehi cl e.
(18) Connect the battery negati ve cabl e.
(19) Start the engi ne and check for l eaks.
INTAKE MANIFOLD5. 2/5. 9L ENGINE
REMOVAL
The al umi num i ntake mani fol d i s a si ngl e pl ane
desi gn wi th equal l ength runners. The mani fol d i s
seal ed by fl ange si de gaskets wi th front and rear
cross-over gaskets. The i ntake mani fol d has i nternal
EGR.
(1) Di sconnect the battery negati ve cabl e.
(2) Drai n the cool i ng system (refer to Group 7,
Cool i ng System for the proper procedures).
(3) Remove the generator (refer to Group 8B Bat-
tery/Starti ng/Chargi ng Systems).
(4) Remove the ai r cl eaner.
(5) Remove the fuel suppl y l i ne and fuel rai l (refer
to Group 14, Fuel System).
(6) Di sconnect the accel erator l i nkage and, i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(7) Remove the di stri butor cap and wi res.
(8) Di sconnect the coi l wi res.
(9) Di sconnect the heat i ndi cator sendi ng uni t
wi re.
(10) Di sconnect the heater hoses and bypass hose.
(11) Remove the cl osed crankcase venti l ati on and
evaporati on control systems.
(12) Remove the A/C compressor bol ts and set the
compressor on the fan shroud.
(13) Remove the support bracket from the i ntake
mani fol d and the mounti ng bracket.
(14) Remove i ntake mani fol d bol ts.
(15) Li ft the i ntake mani fol d and throttl e body out
of the engi ne compartment as an assembl y.
(16) Remove and di scard the fl ange si de gaskets
and the front and rear cross-over gaskets.
Fig. 9 Engine Exhaust/Intake Manifold
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD ZJ
REMOVAL AND INSTALLATION (Continued)
(17) Remove the throttl e body bol ts and l i ft the
throttl e body off the i ntake mani fol d. Di scard the
throttl e body gasket.
(18) Remove the pl enum pan as fol l ows:
(a) Turn the i ntake mani fol d upsi de down. Sup-
port the mani fol d.
(b) Remove the bol ts and l i ft the pan off the
mani fol d. Di scard the gasket.
INSTALLATION
(1) I nstal l the pl enum pan, i f removed, as fol l ows:
(a) Turn the i ntake mani fol d upsi de down. Sup-
port the mani fol d.
(b) Pl ace a new pl enum pan gasket onto the seal
rai l of the i ntake mani fol d. Posi ti on the pan over
the gasket. Al i gn al l the gasket and pan hol es wi th
the i ntake mani fol d.
(c) Hand start al l bol ts.
(d) Ti ghten the bol ts, i n sequence (Fi g. 10), as
fol l ows:
Step 1Ti ghten bol ts to 2.7 Nm (24 i n. l bs.)
torque.
Step 2Ti ghten bol ts to 5.4 Nm (48 i n. l bs.)
torque.
Step 3Ti ghten bol ts to 9.5 Nm (84 i n. l bs.)
torque.
Step 4Check that al l bol ts are ti ghten to 9.5
Nm (84 i n. l bs.) torque.
(2) Usi ng a new gasket, i nstal l the throttl e body
onto the i ntake mani fol d. Ti ghten the bol ts to 23 Nm
(200 i n. l bs.) torque.
(3) Pl ace the 4 pl asti c l ocator dowel s i nto the hol es
i n the bl ock (Fi g. 11).
(4) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent, to the four corner joi nts. An exces-
si ve amount of seal ant i s not requi red to ensure a
l eak proof seal . However, an excessi ve amount of
seal ant may reduce the effecti veness of the fl ange
gasket. The seal ant shoul d be sl i ghtl y hi gher than
the cross-over gaskets, approxi matel y 5 mm (0.2 i n).
(5) I nstal l the front and rear cross-over gaskets
onto the dowel s (Fi g. 11).
(6) I nstal l the fl ange gaskets. Ensure that the ver-
ti cal port al i gnment tab i s resti ng on the deck face of
the bl ock. Al so the hori zontal al i gnment tabs must be
i n posi ti on wi th the mati ng cyl i nder head gasket tabs
(Fi g. 12). The words MANI FOLD SI DE shoul d be vi s-
i bl e on the center of each fl ange gasket.
(7) Careful l y l ower i ntake mani fol d i nto posi ti on
on the cyl i nder bl ock and cyl i nder heads. Use the
al i gnment dowel s i n the cross-over gaskets to posi -
ti on the i ntake mani fol d. After i ntake mani fol d i s i n
pl ace, i nspect to make sure seal s are i n pl ace.
(8) The fol l owi ng torque sequence dupl i cates the
expected resul ts of the automated assembl y system
(Fi g. 13).
Step 1Ti ghten bol ts 1 through 4, i n sequence,
to 8 Nm (72 i n. l bs.) torque. Ti ghten i n al ternati ng
steps 1.4 Nm (12 i n. l bs.) torque at a ti me.
Step 2Ti ghten bol ts 5 through 12, i n sequence,
to 8 Nm (72 i n. l bs.) torque.
Step 3Check that al l bol ts are ti ghten to 8
Nm (72 i n. l bs.) torque.
Step 4Ti ghten al l bol ts, i n sequence, to 16 Nm
(12 ft. l bs.) torque.
Step 5Check that al l bol ts are ti ghten to 16
Nm (12 ft. l bs.) torque.
Fig. 10 Plenum Pan Bolt Tightening Sequence
Fig. 11 Cross-Over Gaskets and Locator Dowels
ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)
(9) I nstal l cl osed crankcase venti l ati on and evapo-
rati on control systems.
(10) I nstal l the coi l wi res.
(11) Connect the heat i ndi cator sendi ng uni t wi re.
(12) Connect the heater hoses and bypass hose.
(13) I nstal l di stri butor cap and wi res.
(14) Hook up the return spri ng.
(15) Connect the accel erator l i nkage and, i f so
equi pped, the speed control and transmi ssi on ki ck-
down cabl es.
(16) I nstal l the fuel l i nes and fuel rai l (refer to
Group 14, Fuel System).
(17) I nstal l the support bracket to the i ntake man-
i fol d and the mounti ng bracket.
(18) I nstal l the generator and dri ve bel t. Ti ghten
generator mounti ng bol t to 41 Nm (30 ft. l bs.)
torque. Ti ghten the adjusti ng strap bol t to 23 Nm
(200 i n. l bs.) torque. Refer to Group 7, Cool i ng Sys-
tem for the proper adjusti ng of bel t tensi on.
(19) I nstal l the A/C compressor on the mounti ng
bracket (refer to Group 24, Heati ng and Ai r Condi -
ti oni ng).
(20) I nstal l the ai r cl eaner.
(21) Fi l l cool i ng system (refer to Group 7, Cool i ng
System for the proper procedure).
(22) Connect the battery negati ve cabl e.
EXHAUST MANIFOLD5. 2/5. 9L ENGINE
REMOVAL
Exhaust mani fol ds are LOG type wi th bal anced
fl ow.
(1) Di sconnect the negati ve cabl e from the battery.
(2) Remove the exhaust mani fol d heat shi el ds (Fi g.
14).
(3) Remove the EGR tube (refer to Group 25,
Emi ssi on Control Systems).
(4) Rai se the vehi cl e.
(5) Remove the bol ts and nuts attachi ng the
exhaust pi pe to the exhaust mani fol d.
(6) Lower the vehi cl e.
(7) Remove bol ts, nuts and washers attachi ng
mani fol d to cyl i nder head.
(8) Remove mani fol d from the cyl i nder head.
Fig. 12 Intake Manifold Flange Gasket Alignment
Fig. 13 Intake Manifold Bolt Tightening Sequence
Fig. 14 Exhaust Manifold
Heat Shields (Left Shield Shown)
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD ZJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: If the studs came out with the nuts when
removing the exhaust manifold, install new studs.
(1) Posi ti on the exhaust mani fol ds on the two
studs l ocated on the cyl i nder head. I nstal l coni cal
washers and nuts on these studs (Fi g. 15).
(2) I nstal l new bol t and washer assembl i es i n the
remai ni ng hol es (Fi g. 15). Start at the center arm
and work outward. Ti ghten the bol ts and nuts to 27
Nm (20 ft. l bs.) torque.
(3) Rai se the vehi cl e.
(4) Assembl e the exhaust pi pe to the exhaust man-
i fol d and secure wi th bol ts, nuts and washers.
Ti ghten these nuts to 31 Nm (23 ft. l bs.) torque.
(5) Lower the vehi cl e.
(6) I nstal l the EGR tube (refer to Group 25, Emi s-
si on Control Systems).
CAUTION: The exhaust manifold heat shields MUST
be installed to protect the underhood components.
(7) I nstal l the exhaust mani fol d heat shi el ds.
Ti ghten the nuts to 27 Nm (20 ft. l bs.) torque.
(8) Connect the negati ve cabl e to the battery.
CLEANING AND INSPECTION
INTAKE AND EXHAUST MANIFOLD4. 0L ENGINE
Cl ean the mati ng surfaces of the cyl i nder head and
the mani fol d i f the ori gi nal mani fol d i s to be
i nstal l ed.
INTAKE MANIFOLD 5. 2/5. 9L ENGINE
CLEANING
Cl ean mani fol d i n sol vent and bl ow dry wi th com-
pressed ai r.
Cl ean cyl i nder bl ock front and rear gasket surfaces
usi ng a sui tabl e sol vent.
The pl enum pan rai l must be cl ean and dry (free of
al l forei gn materi al ).
INSPECTION
I nspect mani fol d for cracks.
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ghtedge.
EXHAUST MANIFOLD5. 2/5. 9L ENGINE
CLEANING
Cl ean mati ng surfaces on cyl i nder head and mani -
fol d, wash wi th sol vent and bl ow dry wi th com-
pressed ai r. I nspect mani fol d for cracks.
INSPECTION
I nspect mati ng surfaces of mani fol d for fl atness
wi th a strai ght edge. Seal surfaces must be fl at
wi thi n 0.1 mm (0.004 i nch) overal l .
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Catalytic Converter to Exhaust Pipe
Exhaust Cl amp . . . . . . . . . . . . .48 Nm (35 ft. l bs.)
Exhaust Pipe to Manifold
Nuts . . . . . . . . . . . . . . . . . . . . .31 Nm (23 ft. l bs.)
Exhaust Manifold Heat Shield(5.2L/5.9L)
Nuts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Exhaust Manifold(5.2L/5.9L)
Nuts/Bol ts . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Floor Pan Heat Shield
Bol ts/Nuts. . . . . . . . . . . . . . . . . .5 Nm (45 i n. l bs.)
Generator Mounting
Bol ts . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Intake/Exhaust Manifold(4.0L)
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.)
Intake Manifold(5.2L/5.9L)
Bol ts . . . . . . . . .Refer to Procedure i n Thi s Secti on
Muffler to Catalytic Converter
Exhaust Cl amp . . . . . . . . . . . . .48 Nm (35 ft. l bs.)
Oxygen Sensor
Sensor . . . . . . . . . . . . . . . . . . . .30 Nm (22 ft. l bs.)
PlenumPan(5.2L/5.9L)
Bol ts . . . . . . . .Refer to Procedure i n Thi s Secti on
Rear Tailpipe Hanger
Bol ts . . . . . . . . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Fig. 15 Exhaust Manifold
ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)