exj 11a, JEEP Manuals, Electronic Service Manual (jeep cherokee xj do 2000)
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XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 1
EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
REMOVAL AND INSTALLATION
EXHAUST MANIFOLD AND TURBOCHARGER
EXHAUST MANIFOLD AND TURBOCHARGER
SPECIFICATIONS
DESCRIPTION AND OPERATION
may result in excessive temperatures in the exhaust
system and on the floor pan.
EXHAUST SYSTEM
The basic exhaust system consists of an engine
exhaust manifold, turbocharger,exhaust down pipe,
exhaust
pipe,
exhaust
heat
shield(s),
muffler
and
exhaust tailpipe
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it will transfer objec-
tionable noises originating from the engine to the
body.
When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or
bolt threads, corrosion damage and worn, cracked or
broken
hangers.
Replace
all
components
that
are
badly
corroded
or
damaged.
DO
NOT
attempt
to
Fig. 1 Heat Shields
1 – EXHAUST MANIFOLD HEAT SHIELD
2 – DOWN PIPE HEAT SHIELD
repair.
When replacement is required, use original equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
REMOVAL AND INSTALLATION
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.
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts at turbo down pipe
to exhaust pipe with heat valve lubricant. Allow 5
minutes for penetration..
(3) Disconnect bolts from exhaust pipe to turbo
down pipe (Fig. 2).
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both
the vehicle and the environment from the high tem-
peratures (Fig. 1).
DO NOT allow the engine to operate at fast idle for
extended
periods
(over
5
minutes).
This
condition
 11 - 2
EXHAUST SYSTEM AND TURBOCHARGER
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Use a new clamp and tighten the nuts to 43
N·m torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
MUFFLER AND EXHAUST 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 LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove
Fig. 2 Exhaust Down Pipe to Exhaust Pipe
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
the
front
muffler
clamp
from
the
exhaust pipe and muffler connection.
(3) Remove the rear exhaust tailpipe hanger clamp
and
(4) Remove the clamp nuts at muffler (Fig. 3). To
remove the exhaust pipe from the muffler, apply heat
until the metal becomes cherry red. Disconnect the
exhaust pipe from the muffler. Remove the exhaust
pipe.
remove
the
exhaust
tailpipe
from
the
front
exhaust tailpipe hanger.
(4) Remove the exhaust tailpipe assembly from the
muffler.
INSTALLATION
(1) Install the muffler onto the exhaust pipe.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe hanger. Make sure that
the exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install
the
remaining
clamps
and
the
front
exhaust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-exhaust pipe
clamp to 43 N·m torque.
(6) Lower the vehicle.
(7) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
Fig. 3 Front Pipe to Muffler
EXHAUST MANIFOLD AND TURBOCHARGER
(LHD)
1 – BRACKET
2 – FRONT PIPE
3 – RUBBER ISOLATOR
4 – MUFFLER
REMOVAL
(1) Disconnect the negative battery cable
(2) Disconnect the breather hose from air cleaner
outlet hose (Fig. 4).
INSTALLATION
(1) Assemble exhaust pipe to muffler, loosely to
permit proper alignment of all parts.
(2) Connect the exhaust pipe to the turbo down
pipe manifold. Tighten the bolts to 22.5 N·m torque.
 XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 3
REMOVAL AND INSTALLATION (Continued)
Fig. 5 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
Fig. 4 Engine Compartment
1 – INTAKE MANIFOLD ELBOW
2 – BREATHER HOSE
3 – INNERCOOLER OUTLET HOSE
4 – AIR FILTER COVER
5 – AIR FILTER OUTLET (FRESH AIR) HOSE
6 – INNERCOOLER INLET HOSE
7 – HEATER CORE COOLANT SUPPLY HOSES
(3) Remove the air filter cover and hose from tur-
bocharger, remove the assembly (Fig. 4).
(4) Remove the EGR vacuum supply hose from the
EGR valve.
(5) Remove the innercooler inlet and outlet hoses
from the engine (Fig. 4).
(6) Remove the (2) bolts holding the EGR tube to
the EGR valve.
(7) Remove the intake manifold elbow and EGR
valve as an assembly.
(8) Raise the vehicle on a hoist.
(9) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(10) Remove
the
exhaust
system
support
clamp
(Fig. 5).
(11) Disconnect the exhaust system at the (3) bolt
flange (Fig. 5).
Fig. 6 Exhaust Downpipe Heatshield
1 – EXHAUST MANIFOLD DOWNPIPE HEATSHIELD RETAINING
STRAPS
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(16) Remove the (2) exhaust manifold heatshield
retaining bolts and remove the heatshield.
(17) Remove the heater supply and return hoses
from the vehicle.
(18) Remove
(12) Unstrap
the
exhaust
downpipe
heatshield
(Fig. 6).
(13) Disconnect the turbocharger oil return hose
from the engine block (Fig. 7).
(14) Lower the vehicle from the hoist.
(15) Remove the EGR tube from exhaust manifold.
the
oil
pressure
supply
line
bango
bolt from the turbocharger.
11 - 4
EXHAUST SYSTEM AND TURBOCHARGER
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REMOVAL AND INSTALLATION (Continued)
Fig. 7 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
Fig. 8 Turbocharger / Exhaust Manifold Assembly
1 – OIL RETURN LINE
2 – WASTEGATE VACUUM SUPPLY HOSE
3 – TURBO TO EXHAUST MANIFOLD RETAINING NUTS
4 – BENCH VISE
5 – TURBOCHARGER ASSEMBLY (REMOVED FROM VEHICLE)
6 – WASTEGATE VACUUM ACTUATOR
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(3) Install the exhaust manifold and turbocharger
assembly in the vehicle
(4) Install the (8) exhaust manifold retaining nuts.
Torque nuts to 32 N·m (23 ft. lbs.).
(5) Install the exhaust manifold downpipe. Torque
bolts to 32 N·m (23 ft. lbs.).
(19) Remove the exhaust downpipe heatshield by
pulling straight up.
(20) Remove the (5) bolts attaching the exhaust
downpipe to the turbocharger and remove pipe.
(21) Remove the (8) exhaust manifold retaining
bolts, it is necessary to access the bolt behind the
manifold outlet from the underneath of the vehicle.
(22) Remove
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
the
exhaust
manifold
and
turbo-
charger assembly from the vehicle
(23) Place assembly in a vice to remove the (3)
exhaust manifold to turbocharger retaining nuts (Fig.
8).
(6) Slide the exhaust downpipe heatshield down
over pipe. Do not attempt to strap heatshield in posi-
tion at this time, wait until vehicle is raised on hoist.
(7) Install the oil supply line on turbocharger.
Torque bango bolt fitting to 27 N·m (20 ft. lbs.).
(8) Connect the heater hoses.
(9) Position and install the exhaust manifold heat-
shield. Torque bolts to 11 N·m (97 in. lbs.).
(10) Raise the vehicle on a hoist.
(11) Connect the turbocharger oil return line to the
engine block (Fig. 9).
(12) Strap the exhaust downpipe heatshield in its
original position.
(13) Install
Cleaning
Always use new gaskets during assembly. All gas-
ket mating surfaces must be cleaned of old gasket
material to produce a smooth and dirt free sealing
surface for the new gasket.
INSTALLATION
(1) Transfer the oil return line to the new turbo-
charger (Fig. 8).
(2) Install the turbo on the exhaust manifold (Fig.
8). Torque the nuts to 32 N·m (23 ft. lbs.).
the
exhaust
system
support
clamp
(Fig. 10). Torque nuts to 23 N·m (17 ft. lbs.).
XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 5
REMOVAL AND INSTALLATION (Continued)
(16) Install the intake manifold elbow and EGR
valve as an assembly. Torque bolts to 27 N·m (20 ft.
lbs.).
(17) Install the (2) bolts holding the EGR tube to
the EGR valve. Torque bolts to 27 N·m (20 ft. lbs.).
(18) Install the innercooler inlet and outlet hoses
on the engine (Fig. 11).
Fig. 9 Turbocharger Oil Return Hose
1 – VEHICLE UNDERBODY
2 – RIGHT ENGINE MOUNT THROUGHBOLT NUT
3 – TURBOCHARGER OIL RETURN HOSE
4 – EXHAUST MANIFOLD DOWNPIPE
5 – TURBOCHARGER
(14) Connect the exhaust system at the (3) bolt
flange (Fig. 10). Torque the bolts to 23 N·m (17 ft.
lbs.).
Fig. 11 Engine Compartment
1 – INTAKE MANIFOLD ELBOW
2 – BREATHER HOSE
3 – INNERCOOLER OUTLET HOSE
4 – AIR FILTER COVER
5 – AIR FILTER OUTLET (FRESH AIR) HOSE
6 – INNERCOOLER INLET HOSE
7 – HEATER CORE COOLANT SUPPLY HOSES
(19) Install the EGR vacuum supply hose on the
EGR valve.
(20) Install the air filter cover and outlet hose on
turbocharger (Fig. 11).
(21) Connect the breather hose on the air cleaner
outlet hose (Fig. 11).
(22) Fill
the
cooling
system.
Refer
to
Group
7,
Cooling System for procedure.
(23) Connect the negative battery cable
(24) Start the engine and check for leaks.
EXHAUST MANIFOLD AND TURBOCHARGER
(RHD)
Fig. 10 Exhaust System Inlet Pipe Connection
1 – EXHAUST INLET PIPE RETAINING BOLTS
2 – EXHAUST SYSTEM SUPPORT CLAMP
REMOVAL
(1) Disconnect the negative battery cable
(2) Disconnect
the
breather
hose
from
the
air
cleaner outlet hose.
(15) Lower the vehicle from the hoist.
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