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XJ
EXHAUST SYSTEM AND TURBOCHARGER
11 - 1
EXHAUST SYSTEM AND TURBOCHARGER
CONTENTS
page
page
GENERAL INFORMATION
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION
EXHAUST MANIFOLD AND TURBOCHARGER
(LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST MANIFOLD AND TURBOCHARGER
(RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 10
MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 2
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10
3
5
GENERAL INFORMATION
EXHAUST SYSTEM
The basic exhaust system consists of an engine
exhaust manifold, exhaust pipe, exhaust heat
shield(s), muffler and exhaust tailpipe.
The exhaust system uses a single muffler.
The exhaust system must be properly aligned to
prevent stress, leakage and body contact. If the sys-
tem contacts any body panel, it may amplify objec-
tionable 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 equip-
ment parts (or equivalent). This will assure proper
alignment and provide acceptable exhaust noise lev-
els.
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 tempera-
tures and objectionable fumes.
EXHAUST HEAT SHIELDS
Exhaust heat shields are needed to protect both
the vehicle and the environment from the high tem-
peratures (Fig. 1).
DO NOT allow the engine to operate at fast idle for
extended periods (over 5 minutes). This condition
may result in excessive temperatures in the exhaust
system and on the floor pan.
Fig. 1 Heat Shields
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EXHAUST SYSTEM AND TURBOCHARGER
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REMOVAL AND INSTALLATION
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
INSTALLATION
(1) Assemble exhaust pipe to muffler, loosely to
permit proper alignment of all parts.
(2) Connect the exhaust pipe to the turbo down
pipe manifold. Tighten the bolts to 22.5 N·m torque.
(3) Use a new clamp and tighten the nuts to 43
N·m torque.
(4) Lower the vehicle.
(5) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts at turbo down pipe
to exhaust pipe with heat valve lubricant. Allow 5
minutes for penetration.
(3) Disconnect bolts from exhaust pipe to turbo
down pipe (Fig. 2).
MUFFLER AND EXHAUST TAILPIPE
All original equipment exhaust systems are manu-
factured with the exhaust tailpipe welded to the muf-
fler. Service replacement mufflers and exhaust
tailpipes are either clamped together or welded
together.
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front muffler clamp from the
exhaust pipe and muffler connection.
(3) Remove the rear exhaust tailpipe hanger clamp
and remove the exhaust tailpipe from the front
exhaust tailpipe hanger.
(4) Remove the exhaust tailpipe assembly from the
muffler.
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe
(4) Remove the clamp nuts at muffler (Fig. 3). To
remove the exhaust pipe from the muffler, apply heat
until the metal becomes cherry red. Disconnect the
exhaust pipe from the muffler. Remove the exhaust
pipe.
INSTALLATION
(1) Install the muffler onto the exhaust pipe.
Install the clamp and tighten the nuts finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe hanger. Make sure that
the exhaust tailpipe has sufficient clearance from the
floor pan.
(4) Install the remaining clamps and the front
exhaust tailpipe hanger.
(5) Tighten the nuts on the muffler-to-exhaust pipe
clamp to 43 N·m torque.
(6) Tighten the nuts on the muffler-to-exhaust pipe
clamp to 43 N·m torque.
(7) Lower the vehicle.
(8) Start the engine and inspect for exhaust leaks
and exhaust system contact with the body panels.
Adjust the alignment, if needed.
Fig. 3 Front Pipe to Muffler
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REMOVAL AND INSTALLATION (Continued)
EXHAUST SYSTEM AND TURBOCHARGER
11 - 3
EXHAUST MANIFOLD AND TURBOCHARGER
(LHD)
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the breather hose from air cleaner
outlet hose (Fig. 4).
Fig. 5 Exhaust System Inlet Pipe Connection
Fig. 4 Engine Compartment
(3) Remove the air filter cover and hose from tur-
bocharger, remove the assembly (Fig. 4).
(4) Remove the EGR vacuum supply hose from the
EGR valve.
(5) Remove the innercooler inlet and outlet hoses
from the engine (Fig. 4).
(6) Remove the (2) bolts holding the EGR tube to
the EGR valve.
(7) Remove the intake manifold elbow and EGR
valve as an assembly.
(8) Raise the vehicle on a hoist.
(9) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(10) Remove the exhaust system support clamp
(Fig. 5).
(11) Disconnect the exhaust system at the (3) bolt
flange (Fig. 5).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(12) Unstrap the exhaust downpipe heatshield
(Fig. 6).
(13) Disconnect the turbocharger oil return hose
from the engine block (Fig. 7).
Fig. 6 Exhaust Downpipe Heatshield
(14) Lower the vehicle from the hoist.
(15) Remove the EGR tube from exhaust manifold.
(16) Remove the (2) exhaust manifold heatshield
retaining bolts and remove the heatshield.
(17) Remove the heater core supply hoses from the
vehicle.
(18) Remove the oil pressure supply line bango
bolt from the turbocharger.
11 - 4
EXHAUST SYSTEM AND TURBOCHARGER
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REMOVAL AND INSTALLATION (Continued)
Fig. 7 Turbocharger Oil Return Hose
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(19) Remove the exhaust downpipe heatshield by
pulling straight up.
(20) Remove the (5) bolts from exhaust manifold
downpipe and remove pipe.
(21) Remove the (8) exhaust manifold retaining
bolts, it is necessary to access the bolt behind the
manifold outlet from the underneath of the vehicle.
(22) Remove the exhaust manifold and turbo-
charger assembly from the vehicle.
(23) Place assembly in a vice to remove the (3)
exhaust manifold to turbocharger retaining nuts (Fig.
8).
Fig. 8 Turbocharger / Exhaust Manifold Assembly
Cleaning
All old gaskets should be inspected for any tears or
signs of prior leakage. If any gaskets show such indi-
cations, they should be replaced with new gaskets.
All gasket mating surfaces must be cleaned of old
gasket material to produce a smooth and dirt free
sealing surface for the new gasket.
Fig. 9 Turbocharger / Exhaust Manifold Assembly
(5) Install the exhaust manifold downpipe. Torque
bolts to 32 N·m (23 ft. lbs.).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(6) Slide the exhaust downpipe heatshield down
over pipe. Do not attempt to strap heatshield in posi-
tion at this time, wait until vehicle is raised on hoist.
INSTALLATION
(1) Transfer the oil return hose to the new turbo-
charger (Fig. 9).
(2) Install the turbo on the exhaust manifold (Fig.
9). Torque the nuts to 32 N·m (23 ft. lbs.).
(3) Install the exhaust manifold and turbocharger
assembly in the vehicle.
(4) Install the (8) exhaust manifold retaining nuts.
Torque nuts to 32 N·m (23 ft. lbs.).
XJ
REMOVAL AND INSTALLATION (Continued)
(7) Install the oil pressure supply line on turbo-
charger. Torque bango bolt fitting to 27 N·m (20 ft.
lbs.).
(8) Install the heater core supply hoses.
(9) Position and install the exhaust manifold heat-
shield. Torque bolts to 11 N·m (97 in. lbs.).
(10) Raise the vehicle on a hoist.
(11) Install the turbocharger oil return hose on the
engine block (Fig. 10).
EXHAUST SYSTEM AND TURBOCHARGER
11 - 5
Fig. 11 Exhaust System Inlet Pipe Connection
Fig. 10 Turbocharger Oil Return Hose
(12) Strap the exhaust downpipe heatshield in its
original position.
(13) Connect the exhaust system at the (3) bolt
flange (Fig. 11). Torque the bolts to 23 N·m (17 ft.
lbs.).
(14) Install the exhaust system support clamp
(Fig. 11). Torque nuts to 23 N·m (17 ft. lbs.).
(15) Lower the vehicle from the hoist.
(16) Install the intake manifold elbow and EGR
valve as an assembly. Torque bolts to 27 N·m (20 ft.
lbs.).
(17) Install the (2) bolts holding the EGR tube to
the EGR valve. Torque bolts to 27 N·m (20 ft. lbs.).
(18) Install the innercooler inlet and outlet hoses
on the engine (Fig. 12).
(19) Install the EGR vacuum supply hose on the
EGR valve.
(20) Install the air filter cover and outlet hose on
turbocharger (Fig. 12).
(21) Connect the breather hose on the air cleaner
outlet hose (Fig. 12).
(22) Fill the cooling system. Refer to Group 7,
Cooling System for procedure.
(23) Connect the negative battery cable
Fig. 12 Engine Compartment
(24) Start the engine and check for leaks.
EXHAUST MANIFOLD AND TURBOCHARGER
(RHD)
REMOVAL
(1) Disconnect the negative battery cable.
(2) Disconnect the breather hose from the air
cleaner outlet hose.

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