Emissions Components - Removal/Installation

D. REPLACE OXYGEN SENSOR:

Warning:
Exhaust manifold becomes very hot during engine operation. Make sure engine has cooled sufficiently before attempting oxygen sensor replacement.





1. Locate the oxygen sensor in the exhaust manifold (Figure 7).
2. Disconnect oxygen sensor electrical connector.
3. Remove oxygen sensor. Apply heat to the sensor, if necessary, to assist removal.
4. Clean exhaust manifold threads with a thread chaser.

Note:
Do not use solvents or lubricants on threads.

5. Install provided oxygen sensor. Tighten to 22 ft.lbs. (30 Nm).
6. Connect oxygen sensor electrical connector.

E. INSTALL PCV VACUUM HOSE

(Wrangler (YJ) vehicles only):





1. Locate the PCV vacuum hose (Figure 8).
2. Remove old PCV hose from vacuum tubing and PCV valve.
3. Install provided PCV vacuum hose from emission service package.

F. INSTALL TRANSFER CASE VACUUM HOSE (4WD Vehicles Only):





1. Locate and remove rubber vacuum hose near rear of intake manifold, which connects the metal transfer case vacuum tube to the vacuum port on the intake manifold (Figure 9).
2. Install provided transfer case vacuum hose (Figure 9).

G. REPLACE FUEL TANK VENT VALVE BOOT (YJ Vehicles Equipped With Steel Fuel Tank Only):

1. Raise vehicle on hoist.





2. Pull back splash shield and locate fuel tank vent valve in fuel vent line in right rear fender well of vehicle (Figure 10).
3. Disconnect clamp at small end of boot and pull boot from vent line.
4. Using a sharp utility knife, slice side of rubber boot and remove it from the vent valve. Be careful not to cut the vent valve.
5. Install provided boot on vent valve.

Note:
A few drops of automatic transmission fluid (ATF) may be used to aid boot installation.

6. Install small end of boot on fuel vent line and install clamp.
7. Reinstall splash shield.
8. Lower vehicle.

H. INSTALL RECALL COMPLETION LABEL:

1. With a ball point pen, print your dealer code (5 digits) on the supplied Recall Completion Label.
2. Peel the label from its backing and apply it near the Vehicle Emission Control Information Label.

I. COMPLETE PROOF OF CORRECTION FORM:

1. Complete a Vehicle Emission Recall Proof of Correction Form and supply it to the vehicle owner.