Exhaust System: Description and Operation

EXHAUST SYSTEM

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.

Exhaust System-2.5L Engine:

Exhaust System-4.0L Engine:

The basic exhaust system consists of an engine exhaust manifold, exhaust pipe with oxygen sensor, catalytic converter with oxygen sensor, exhaust heat shield(s), muffler and exhaust tailpipe.
The exhaust system uses a single muffler with a catalytic converter consisting of dual ceramic monoliths.
The 4.0L engines use a seal between the engine exhaust manifold and exhaust pipe to assure a tight seal and strain free connections.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. If the system contacts any body panel, it may amplify objectionable noises originating from the engine or 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 repair.
When replacement is required, use original equipment parts (or their equivalent). This will assure proper alignment and provide acceptable exhaust noise levels.

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 temperatures and objectionable fumes.