Jeep Cherokee

 Service Manual

Exhaust system » Removal and installation
Catalytic converter

WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE FLAME NEAR THE FUEL LINES.

CAUTION: When servicing exhaust system components, disconnect the oxygen sensor connector.

Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.

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 connection 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 separate.

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 alignment slot.

(3) Install a new clamp at the muffler and catalytic converter connection (Fig. 9). Tighten the clamp nut to 61 N·m (45 ft. lbs.) torque.

(4) Coat the oxygen sensor with anti-seize compound.

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.

Exhaust pipe

Catalytic converter

Muffler and tailpipe

Heat shields