Catalytic Converter - Installation

4.0L ENGINE






WARNING: If torches are used when servicing the exhaust system, do not allow any flame near the fuel lines or the fuel tank. Failure to follow these instructions may result in possible serious or fatal injury.

1. Position the front exhaust pipe and catalytic converter assembly isolator (4) into the mount at the transmission (if equipped) and onto the exhaust manifold flange connection.
2. Install the nuts at the front exhaust pipe and catalytic converter assembly to muffler flange. Do not tighten.
3. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
4. Tighten the bolt (1) at exhaust manifold to 36 Nm (28 ft. lbs.) torque.
5. Tighten the front exhaust pipe and catalytic converter assembly to muffler flange nuts to 36 Nm (28 ft. lbs.) torque.
6. Position the front pipe onto the exhaust manifold flange connection. Tighten the clamp to 10 Nm (95 in. lbs.) torque.
7. Connect oxygen sensor electrical connectors.
8. Lower the vehicle.
9. Connect the negative battery cable.
10. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
11. Check the exhaust system for any contact with the body panels. Make adjustments, if necessary.