2012 Jeep Wrangler JK Factory Service Manual 11 - Exhaust System

PIPE, Exhaust

REMOVAL

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 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.

CAUTION:

When servicing and/or replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing the exhaust to hang by the oxygen sensor wires will damage the harness and/or oxygen sensor.

  1. Raise and support the vehicle (Refer to 04 - Vehicle Quick Reference/Hoisting/Standard Procedure) .

  2.  
  3. Saturate the studs and nuts (1) with a Mopar® rust penetrant. Allow 5 minutes for penetration.

  4.  
  5. Disconnect the oxygen sensor connectors and remove the sensors from the exhaust pipe (2) and the catalytic converter.

  6.  
  7. Remove the exhaust pipe to catalytic converter nuts (1).

  8.  
  9. Remove the exhaust pipe to muffler flange retaining nuts.

  10.  
  11. Slide the exhaust pipe (2) rearward until the exhaust pipe hanger disengages from the transmission support. Remove the exhaust pipe (2) from the vehicle.

  12.  

INSTALLATION

INSTALLATION


  1. Position the exhaust pipe (2) into the vehicle.

  2.  
  3. Insert the exhaust pipe hanger into the transmission support.

  4.  
  5. Install the exhaust pipe to the catalytic converter flange retaining nuts (1). Do not tighten nuts.

  6.  
  7. Install the exhaust pipe to the muffler mounting bolts. Do not tighten bolts.

  8.  
  9. Make sure the exhaust pipe/exhaust system is aligned and has the proper clearance. The minimum clearance is 25mm (1 inch). Make the necessary adjustments, if needed.

  10.  
  11. Tighten the exhaust pipe to catalytic converter flange retaining nuts (1) to 27 N·m (19 ft. lbs.).

  12.  
  13. Tighten the exhaust pipe to muffler mounting bolts to 31 N·m (23 ft. lbs.).

  14.  
  15. Install the oxygen sensors. Tighten sensor to 50 N·m (37 ft. lbs.).

  16.  
  17. Cconnect oxygen sensor wire harness connectors.

  18.  
  19. Lower the vehicle.

  20.  
  21. Start the engine and inspect for leaks. Repair exhaust leaks as necessary.

  22.  
  23. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

  24.