PIPE-EXHAUST
REMOVAL
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.
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(s). Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and/or sensor.
1. Raise and support the vehicle.
2. Saturate the studs and nuts with a Mopar® rust penetrant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor connectors and remove sensors from the exhaust pipe and the catalytic converter.
4. Disconnect the catalytic converter from the engine exhaust manifold.
5. Remove exhaust pipe to muffler flange retaining nuts.
6. Slide exhaust pipe forward until exhaust pipe hanger disengages from transmission support. Remove exhaust pipe and catalytic converter from vehicle.
INSTALLATION
1. Position exhaust pipe and catalytic converter into vehicle.
2. Insert exhaust pipe hanger into transmission support.
3. Make sure the exhaust system is aligned and has the proper clearance. The minimum clearance is 25mm (1 inch).
4. Tighten muffler to catalytic converter flange retaining nuts to 28 N·m (21 ft. lbs.).
5. Tighten exhaust pipe to exhaust manifold mounting bolts to 31 N·m (23 ft. lbs.).
6. Install the oxygen sensors in the exhaust pipe and catalytic converter and connect oxygen sensor connectors.
7. Lower vehicle.
8. Start engine and inspect for leaks. Repair exhaust leaks as necessary.
9. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.