Cylinder Head JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

(4) Install flex plate. Apply MopartLock & Seal
Adhesive to bolt threads and tighten bolts to 95 N´m
(70 ft. lbs.).
(5) Install the transmission.
PISTON & CONNECTING ROD
DESCRIPTION
The pistons are made of a cast aluminum alloy.
The pistons have pressed-in pins attached to forged
powdered metal connecting rods. The pistons pin is
offset 1 mm (0.0394 in.) towards the thrust side of
the piston. The connecting rods are a cracked cap
design and are not repairable. Hex head cap screws
are used to provide alignment and durability in the
assembly. The pistons and connecting rods are ser-
viced as an assembly.
OPERATION
The piston and connecting rod is the link between
the combustion force to the crankshaft.
REMOVAL
NOTE: Cylinder Head must be removed before Pis-
tons and Rods. Refer to Cylinder Head Removal in
this section.
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block.Be sure to keep tops of pistons
covered during this operation. Mark piston with
matching cylinder number (Fig. 60).
(2) Remove oil pan. Scribe the cylinder number on
the side of the rod and cap (Fig. 61) for identification.
(3) Pistons have a directional stamping in the
front half of the piston facing towards thefrontof
engine.
(4) Pistons and connecting rods must be removed
from top of cylinder block. Rotate crankshaft so that
each connecting rod is centered in cylinder bore.
(5) Remove Balance Shaft Assembly. Refer to Bal-
ance Shaft Removal in this section.
(6) Remove connecting rod cap bolts. Push each
piston and rod assembly out of cylinder bore.
NOTE: Be careful not to nick crankshaft journals.
(7) After removal, install bearing cap on the mat-
ing rod.
(8) Piston and Rods are serviced as an assembly.
Fig. 59 Rear Crankshaft SealÐInstallation
1 - SPECIAL TOOL 6926±2 INSTALLER
Fig. 60 Piston Markings
1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
9s - 40 ENGINEKJ
CRANKSHAFT OIL SEAL - REAR (Continued)

INSTALLATION
(1) Before installing pistons and connecting rod
assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line with
oil ring rail gap.
(2) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 62). As viewed
from top.
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
(Fig. 63).Be sure position of rings does not
change during this operation.
(4) The directional stamp on the piston should face
toward the front of the engine.
(5) Rotate crankshaft so that the connecting rod
journal is on the center of the cylinder bore. Insert
rod and piston assembly into cylinder bore and guide
rod over the crankshaft journal.(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
NOTE: The connecting rod cap bolts should not be
reused.
(7) Before installing theNEWbolts the threads
should be coated with clean engine oil.
(8) Install each bolt finger tight than alternately
torque each bolt to assemble the cap properly.
CAUTION: Do not use a torque wrench for second
part of last step.
(9) Tighten the bolts to 54 N´m PLUS 1/4 turn (40
ft. lbs. PLUS 1/4 turn).
(10) Using a feeler gauge, check connecting rod
side clearance (Fig. 64).
Fig. 61 Identify Connecting Rod to Cylinder
Fig. 62 Piston Ring End Gap Position
1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 63 PistonÐInstallation
Fig. 64 Checking Connecting Rod Side Clearance
KJENGINE9s-41
PISTON & CONNECTING ROD (Continued)

LUBRICATION
DESCRIPTION
The lubrication system is a full-flow filtration,
pressure feed type. The oil pump is mounted in the
front engine cover and driven by the crankshaft.
OPERATION
Engine oil drawn up through the pickup tube and
is pressurized by the oil pump and routed through
the full-flow filter to the main oil gallery running the
length of the cylinder block. A diagonal hole in each
bulkhead feeds oil to each main bearing. Drilled pas-
sages within the crankshaft route oil from main bear-
ing journals to connecting rod journals. Balance shaft
lubrication is provided through an oil passage from
the number one main bearing cap through the bal-
ance shaft carrier support leg. This passage directly
supplies oil to the front bearings and internal
machined passages in the shafts that routes oil from
front to the rear shaft bearing journals. A vertical
hole at the number five bulkhead routes pressurized
oil through a restrictor (integral to the cylinder head
gasket) up past a cylinder head bolt to an oil gallery
running the length of the cylinder head. The cam-
shaft journals are partially slotted to allow a prede-
termined amount of pressurized oil to pass into the
bearing cap cavities. Lubrication of the camshaft
lobes are provided by small holes in the camshaft
bearing caps that are directed towards each lobe. Oil
returning to the pan from pressurized components
supplies lubrication to the valve stems. Cylinder
bores and wrist pins are splash lubricated from
directed slots on the connecting rod thrust collars.
DIAGNOSIS AND TESTING - ENGINE OIL
PRESSURE CHECKING
(1) Disconnect and remove oil pressure switch.
(Refer to 9 - ENGINE/LUBRICATION/OIL PRES-
SURE SENSOR/SWITCH - REMOVAL)
(2) Install Special Tools C-3292 Gauge with 8406
Adaptor fitting.
(3) Start engine and record oil pressure. Refer to
Specifications for correct oil pressure requirements.
(Refer to 9 - ENGINE - SPECIFICATIONS)
CAUTION: If oil pressure is 0 at idle, do not perform
the 3000 RPM test
(4) If oil pressure is 0 at idle. Shut off engine,
check for pressure relief valve stuck open, a clogged
oil pick-up screen or a damaged oil pick-up tube
O-ring.
(5) After test is complete, remove test gauge and
fitting.
Fig. 76 TRANSMISSION MOUNT 3.7L 2WD AUTO
TRANS
1 - BOLT
2 - MOUNT
Fig. 77 TRANSMISSION MOUNT 3.7L 4WD AUTO
TRANS
1 - MOUNT
2 - BOLT
9s - 46 ENGINEKJ
LUBRICATION (Continued)

(7) Install crankshaft sprocket using Special Tool
6792 (Fig. 89).
(8) Install oil pump pick-up tube.(9) Install oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - INSTALLATION)
(10) Install timing belt rear cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(11) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
INTAKE MANIFOLD
DESCRIPTION
The intake manifold is a one piece composite mod-
ule that attaches to the cylinder head with fasteners.
The manifold is a long branch design to enhance low
and mid-range torque
OPERATION
The intake manifold delivers air to the combustion
chambers. This air allows the fuel delivered by the
fuel injectors to ignite when the spark plug fire.
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engine.
Fig. 87 Oil Pump Sealing - Typical
1 - O-RING
2 - SEALER LOCATION
Fig. 88 Front Crankshaft Seal - Installation
1 - PROTECTOR
2 - SEAL
3 - SPECIAL TOOL 6780
Fig. 89 Crankshaft Sprocket - Installation
1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
KJENGINE9s-51
OIL PUMP (Continued)

(2) Spray a small stream of water (Spray Bottle) at
the suspected leak area.
(3) If engine RPM'S change, the area of the sus-
pected leak has been found.
(4) Repair as required.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect connector from inlet air tempera-
ture sensor.
(3) Disconnect air intake tube at throttle body and
remove upper air cleaner housing.
(4) Disconnect connector from throttle position
sensor (TPS).
(5) Disconnect connector from idle air control (IAC)
motor.
(6) Disconnect connector from MAP sensor.
(7) Remove vacuum lines for purge solenoid and
PCV valve at intake manifold.
(8) Remove vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at intake manifold fittings.
(9) Disconnect throttle, speed control (if equipped),
and transaxle control (if equipped) and cables from
throttle lever and bracket. (Refer to 14 - FUEL SYS-
TEM/FUEL INJECTION/THROTTLE CONTROL
CABLE - REMOVAL)
(10) Perform fuel system pressure release proce-
durebefore attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(11) Disconnect fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(12) Disconnect coolant temperature sensor/fuel
injector wire harness connector.
(13) Disconnect fuel injector harness.
(14) Remove intake manifold to cylinder head fas-
teners.
(15) Remove the manifold from engine.
CAUTION: Cover intake manifold openings to pre-
vent foreign material from entering engine.
(16) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION)
INSPECTION
(1) Check manifold surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (0.006 in. per foot) of manifold length.
(2) Inspect manifold for cracks or distortion.
Replace manifold if necessary.
INSTALLATION
(1) Clean manifold sealing surfaces.
(2) Install new manifold to cylinder head seals.
(3) Install manifold to head.
(4) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown (Fig. 90).
Repeat procedure until all bolts are at specified
torque.
(5) Install throttle cables in bracket.
(6) Connect throttle, speed control, (if equipped),
cables to throttle lever.
(7) Connect vacuum lines for power brake booster,
LDP, EGR transducer, and speed control vacuum res-
ervoir (if equipped) at upper intake manifold fittings.
(8) Connect vacuum lines for purge solenoid and
PCV valve.
(9) Connect electrical connectors for MAP sensor,
throttle position sensor (TPS), and idle air control
(IAC) motor.
(10) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(11) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(12) Install the air cleaner housing and air intake
tube to throttle body.
(13) Connect inlet air temperature sensor connec-
tor.
(14) Connect negative cable to battery.
Fig. 90 LOWER INTAKE MANIFOLD TIGHTENING
SEQUENCE
9s - 52 ENGINEKJ
INTAKE MANIFOLD (Continued)

EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Lower the vehicle.
(3) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(4) Remove the air cleaner bracket (Fig. 91).
(5) Remove the heat shield.
(6) Remove the bolts attaching the manifold to the
cylinder head.
(7) Remove exhaust manifold.
(8) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Clean the manifold mating surfaces.
(2) Install exhaust manifold with a new gasket.
Tighten attaching nuts to 20 N´m (175 in. lbs.).
(3) Attach exhaust pipe to exhaust manifold and
tighten fasteners to 37 N´m (27 ft. lbs.).
(4) Install and connect the oxygen sensor. (Refer to
14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR
- COMPONENT LOCATION)
(5) Install the heat shield.
(6) Install the air cleaner bracket.
TIMING BELT COVER(S)
REMOVAL
FRONT COVER
(1) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
DAMPER - REMOVAL)
(2) Remove generator drive belt tensioner assem-
bly. (Refer to 7 - COOLING/ACCESSORY DRIVE/
BELT TENSIONERS - REMOVAL)
(3) Remove timing belt front cover bolts, and
remove covers.
REAR COVER
(1) Remove front covers.
(2) Remove timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(3) Hold camshaft sprocket with Special Tool 6847
while removing center bolt.
(4) Remove timing belt idler pulley.
(5) Remove rear cover fasteners and remove cover
from engine.
INSTALLATION
REAR COVER
(1) Install timing belt rear cover and bolts (Fig.
92). Torque bolts to 12 N´m (105 in. lbs).
Fig. 91 AIR CLEANER BRACKET
1 - AIR CLEANER BRACKET
2 - BOLT (2)
KJENGINE9s-53

CAUTION: Do not use an impact wrench for tighten-
ing camshaft sprocket bolt. Damage to the timing
locating pin can occur. Hand tighten using a
wrench ONLY.
(2) Install camshaft sprockets, and camshaft target
ring. Hold sprockets with Special Tool 6848 and
tighten center bolt to 101 N´m (75 ft. lbs.).
(3) Install timing belt idler pulley and tighten
mounting bolt to 61 N´m (45 ft. lbs.).
(4) Install timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
(5) Install accessory drive bracket (Fig. 93).
(6) Install front covers.
FRONT COVER
(1) Install timing belt front covers (Fig. 94).
Tighten fasteners to 7 N´m (60 in. lbs.).
(2) Install generator drive belt tensioner. (Refer to
7 - COOLING/ACCESSORY DRIVE/BELT TEN-
SIONERS - INSTALLATION)
(3) Install crankshaft vibration damper. (Refer to 9
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION)
Fig. 92 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
Fig. 93 ACCESSORY DRIVE BRACKET
1- UPPER TIMING BELT COVER
2- LOWER TIMING BELT COVER
3- BELT TENSIONER
4- ACCESSORY DRIVE BRACKET
Fig. 94 TIMING BELT COVERS
1- UPPER TIMING BELT COVER
2- REAR TIMING BELT COVER
3- LOWER TIMING BELT COVER
4- ACCESSORY DRIVE BRACKET NOT SHOWN
9s - 54 ENGINEKJ
TIMING BELT COVER(S) (Continued)

TIMING BELT TENSIONER &
PULLEY
REMOVAL
(1) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(2) Remove timing belt idler pulley.
(3) Hold camshaft sprocket with Special Tool 6847
while removing bolt (Fig. 104). Remove both cam
sprockets.
(4) Remove rear timing belt cover fasteners and
remove cover from engine (Fig. 105).
(5) Remove lower bolt attaching timing belt ten-
sioner assembly to engine and remove tensioneras
an assembly.
INSTALLATION
(1) Align timing belt tensioner assembly to engine
and install lower mounting boltbut do not tighten.
To properly align tensioner assemblyÐinstall one of
the engine bracket mounting bolts (M10) 5 to 7 turns
into the tensioner's upper mounting location.
(2) Torque the tensioner's lower mounting bolt to
61 N´m (45 ft. lbs.). Remove the upper bolt used for
tensioner alignment.
(3) Install rear timing belt cover and fasteners.
(4) Install timing belt idler pulley and torque
mounting bolt to 61 N´m (45 ft. lbs.).(5) Install camshaft sprockets. Use Special Tool
6847 to hold sprockets, torque bolts to 101 N´m (75
ft. lbs.).
(6) Install the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION)
BALANCE SHAFT
DESCRIPTION
The 2.4L engine is equipped with two nodular cast
iron balance shafts installed in a cast aluminum car-
rier attached to the lower cylinder block (Fig. 106).
OPERATION
The balance shafts are driven by the crankshaft
via a roller chain and sprockets. The balance shafts
are connected by helical gears. The dual counter
rotating shafts decrease second order vertical shak-
ing forces caused by component movement.
Fig. 104 Camshaft Sprocket - Removal/Installation
1 - SPECIAL TOOL 6847
Fig. 105 TIMING BELT REAR COVER FASTENERS
1 - OUTER COVER TO REAR COVER FASTENERS (3)
2 - REAR COVER TO CYLINDER HEAD FASTENERS
3 - OUTER COVER TO REAR COVER FASTENERS (3)
4 - INNER COVER TO BLOCK FASTENERS
KJENGINE9s-59

DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified
torque at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and 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 sensor.
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR 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 CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct thecause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen the nuts from the clamp that hold the
catalytic converter to the exhaust pipe flange connec-
tion.
11 - 2 EXHAUST SYSTEMKJ
EXHAUST SYSTEM (Continued)

DIAGNOSIS AND TESTING - EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified
torque at leaking joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
CAUTION:
When servicing and 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 sensor.
CATALYTIC CONVERTER
DESCRIPTION - CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR 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 CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
CAUTION: DO NOT remove spark plug wires from
plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
occur. If a converter is heat-damaged, correct thecause of the damage at the same time the converter
is replaced. Also, inspect all other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
50 State emission vehicles incorporate two mini
catalytic converters located after the exhaust mani-
folds and before the inline catalytic converter.
REMOVAL
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with heat valve
lubricant. Allow 5 minutes for penetration.
(3) Remove the bolts from the crossover pipe to the
catalytic converter connection.
(4) Disconnect oxygen sensor wiring.
(5) Loosen and remove the nuts from the clamp
that hold the catalytic converter to the exhaust pipe
flange connection.
11s - 2 EXHAUST SYSTEMKJ
EXHAUST SYSTEM (Continued)