Exhaust System Jeep Grand Cherokee WK2

Scheme 1

The 3.6L exhaust system uses two catalytic converters (1) located in the front exhaust pipe and a single muffler (2), with a single resonator/tailpipe assembly.

Scheme 2

The 5.7L exhaust system uses two catalytic converters (1) located in the front exhaust pipe, and a single muffler (2), with a dual resonator/tailpipe assembly (3).

The front exhaust pipe/catalytic converter assembly (1) is a hydra-form thin wall air gap design. This design is used to reduce heat, noise and improve emissions. When replacement is required, use original equipment parts (or their equivalent).

The exhaust manifolds are equipped with ball flange outlets 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.

The basic exhaust system consists of exhaust manifold(s), exhaust pipe with oxygen sensors, catalytic converter(s), muffler and tailpipe.

DIAGNOSIS AND TESTING

EXHAUST SYSTEM DIAGNOSIS CHART

SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 3

The Exhaust Gas Temperature Sensor (7) 1/1 is located the outlet of the Exhaust Manifold and is accessible from the top of the engine compartment. The Exhaust Gas Temperature Sensor 1/1 operates as a typical two wire 5-Volt sensor. It sends a signal to the Powertrain Control Module (PCM) indicating the temperature of the exhaust gases entering the Diesel Particulate Filter.

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Disconnect the negative battery cable.
2. Remove the engine cover (1).
3. Remove the cowl extension (1) and the side extensions (2, 5). Refer to «SILENCER, COWL EXTENSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/gauges-instrument-panels/#body-interior-exterior) .
4. Remove nuts and the HVAC air inlet housing (1).
5. Disconnect the oxygen sensor wire harness connector (1).
6. Disconnect the upstream exhaust temperature sensor wire harness connector.
7. Loosen the clamp (2) and separate the Diesel Particulate Filter (DPF) from turbocharger.
8. Remove the exhaust temperature sensor (7).

Scheme 9

Scheme 10

1. Disconnect the negative battery cable.
2. Remove the transmission skid plate. Refer to «PLATE, SKID, TRANSMISSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
3. Disconnect the exhaust temperature sensor wire harness connector (1).
4. Remove the exhaust temperature sensor (1).

EXHAUST TEMPERATURE SENSOR 1/1

1. Install the exhaust temperature sensor (7) and tighten to 45 N.m (33 ft. lbs.).
2. Align the Diesel Particulate Filter (DPF) pipe to the turbocharger. Tighten the clamp (2) to 25 N.m (18 ft. lbs.)
3. Connect the upstream exhaust temperature sensor wire harness connector.
4. Connect the oxygen sensor wire harness connector (1).
5. Install the HVAC air inlet housing (1) and securely tighten nuts.
6. Install the cowl extension silencer. Refer to «SILENCER, COWL EXTENSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/gauges-instrument-panels/#body-interior-exterior) .
7. Install the engine cover (1).
8. Connect the negative battery cable.

EXHAUST TEMPERATURE SENSOR 1/2

1. Install the exhaust temperature sensor (1) and tighten to 47 N.m (35 ft. lbs.).
2. Connect the exhaust temperature sensor wire harness connector (1).
3. Install the transmission skid plate. Refer to «PLATE, SKID, TRANSMISSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
4. Connect the negative battery cable.

Scheme 11

The Exhaust Differential Pressure Sensor (2) is remotely mounted on the transmission housing. Two pressure tubes (3) measure pressure before and after the Diesel Particulate Filter (DPF)/Diesel Oxidation Catalyst (DOC). The sensor is critical for fail-safe of regeneration strategy, because it interprets high pressure drops as possible high soot loads.

Scheme 12

1. Disconnect the negative battery cable.
2. Raise and support vehicle. Refer to «JACKING AND HOISTING LIFT POINTS»(/jeep/grand-cherokee/wk2-2010-2013/remont/fuses-circuit-breakers/#vehicle-quick-reference) .
3. Remove the transmission skid plate. Refer to «PLATE, SKID, TRANSMISSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
4. Disconnect the differential pressure sensor harness connector.
5. Disconnect the differential pressure sensor hoses (2).
6. Remove bolt and the differential pressure sensor.
7. If necessary, remove mounting bolts (3) securing the differential pressure sensor tubing to transmission.
8. If necessary, remove the differential pressure sensor tubing (6) from the diesel particulate filter (4).

INSTALLATION - DIFFERENTIAL PRESSURE SENSOR

1. If removed, install Differential Pressure Sensor tubing (6) into diesel particulate filter (4). Tighten fittings to 30 N.m (22 ft. lbs.).
2. If necessary, install the mounting bolts (4) securing the differential pressure sensor tubing to transmission and securely tighten.
3. Install the differential pressure sensor (2). Tighten bolt (1) to 18 N.m (159 in. lbs.). NOTE: Before installing, inspect both pressure hoses and make sure there is not any dip across the hoses. In cases where water is frozen, a dip across the hoses can cause condensation which can set a MIL.
4. Connect the differential pressure sensor hoses (2).
5. Connect the differential pressure sensor harness connector.
6. Install the transmission skid plate. Refer to «PLATE, SKID, TRANSMISSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
7. Lower the vehicle.
8. Connect the negative battery cable.

Scheme 13

Scheme 14

1. Disconnect the negative battery cable.
2. Lift the vehicle.
3. If equipped, remove skid plates.
4. Separate the muffler/resonator from the DPF outlet pipe.
5. Remove the differential pressure hoses (3).
6. Remove the bolt (4) the secures the pressure lines to the transmission.
7. Remove the temperature sensor (2) from the DPF (3).
8. If equipped, remove the rear transfercase steady bracket (6).
9. Loosen the front steady bracket (7) retainer nut for the DPF clamp.
10. Loosen the clamp (3) and separate the DPF from the downpipe.
11. Separated the DPF outlet pipe from the tailpipe.
12. Remove the DPF (4) from the vehicle.
13. Remove the differential pressure lines (6).

3.0L DIESEL PARTICULATE FILTER (DPF) - INSTALLATION

1. Install the steel differential pressure lines (5).
2. Position the DPF (4) into the vehicle.
3. Align the DPF to the turbocharger down pipe. Tighten the clamp (3) to 25 N.M (18 ft. lbs.)
4. Align and tighten the front steady bracket (7) retainer nut for the DPF bracket to 26 N.M (19 ft. lbs.)
5. If equipped, install the rear transfercase steady bracket (6). Tighten the nuts to 10 N.M (89 in. lbs.) and the bolt to 21 N.M (15 ft. lbs.).
6. Install the differential pressure lines bracket bolt (4).
7. Install the differential pressure hoses (3) to the steel lines.
8. Install the temperature sensors (2).
9. Install the tailpipe assembly.
10. If equipped, install the skid plates (1).
11. Lower vehicle.
12. Connect the negative battery cable.

Scheme 15

The front exhaust pipe/catalytic converter assembly (1) is a hydra-form thin wall air gap design. This design is used to reduce heat, noise and improve emissions. When replacement is required, use original equipment parts (or their equivalent).

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 excessive 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 the cause 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 contaminating the catalyst core.

Scheme 16

Scheme 17

Scheme 18

1. Disconnect negative battery cable.
2. Remove the engine cover.
3. Saturate the exhaust flange bolts with heat valve lubricant. Allow 5 minutes for penetration.
4. Remove the upper catalytic flange bolts (1).
5. Raise and support the vehicle.
6. If equipped, remove skid plates. Refer to «PLATE, SKID, TRANSMISSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
7. Remove the lower catalytic flange bolts (4).
8. Remove transmission crossmember reinforcement brackets (1, 4).
9. Disconnect oxygen sensor (2) electrical connectors.
10. Remove the nuts from the front exhaust pipe/catalytic converter assembly to the muffler flange (2).
11. Remove the front exhaust pipe/catalytic converter assembly (1) from the vehicle.

5.7L ENGINE

Scheme 19

1. Disconnect the negative cable
2. Raise and support the vehicle.
3. If equipped, remove skid plates. Refer to «PLATE, SKID, TRANSMISSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
4. Saturate the bolts (2) and nuts (3) with heat valve lubricant. Allow 5 minutes for penetration.
5. Remove transmission crossmember reinforcement brackets (1, 4).
6. If equipped, Remove the lower heat shield near the front driveshaft.
7. Remove the upstream and the downstream oxygen sensors from the exhaust, refer to appropriate Fuel System article.
8. Remove the nuts from the front exhaust pipe/catalytic converter assembly to muffler flange (2).
9. Remove bolts (4) and flanged nuts (1) at the exhaust manifold.
10. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.

INSPECTION

Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating.

If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core.

Scheme 20

1. Position new exhaust gasket (6) onto flange (1).
2. Position the front exhaust pipe/catalytic converter assemblies (4) into vehicle.
3. Install the lower bolts (5) at the front exhaust pipe/catalytic converter (4) assembly to exhaust manifold (1) flange. Do not tighten.
4. Lower vehicle.
5. Install the upper bolts at the front exhaust pipe/catalytic converter assemblies to exhaust manifold flanges. Tighten bolts to 23 N.m (17 ft. lbs.).
6. Raise vehicle.
7. Tighten lower flange bolts to 23 N.m (17 ft. lbs.).
8. Position the exhaust system for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
9. Tighten the front exhaust pipe/catalytic converter assembly to muffler flange (2) nuts to 47 N.m (35 ft. lbs.) torque.
10. Connect oxygen sensor (2) electrical connectors.
11. Install transmission crossmember reinforcement brackets (1, 4). Tighten bolts to 55 N.m (41 ft. lbs.).
12. If equipped, install skid plates. Refer to «PLATE, SKID, TRANSMISSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
13. Lower vehicle.
14. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.

1. Position the front exhaust pipe/catalytic converter assembly (1) into vehicle.
2. Install the nuts (3) at the front exhaust pipe/catalytic converter assembly to muffler flange at the exhaust manifold (4).
3. Install the bolts (2) at the front exhaust pipe/catalytic converter assembly (4) to exhaust manifold flange. Do not tighten.
4. Tighten the front exhaust pipe and catalytic converter assembly to muffler flange (2) nuts to 47 N.m (35 ft. lbs.) torque.
5. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 in.) is required.
6. Tighten front exhaust pipe/catalytic converter assemblies to exhaust manifold bolts (2) to 30 N.m (22 ft. lbs.) torque.
7. Install the oxygen sensor's, refer to appropriate Fuel System article.
8. If equipped, Install the heat shield for the front drive shaft.
9. Install transmission crossmember reinforcement brackets (1, 4). Tighten bolts to 55 N.m (41 ft. lbs.).
10. If equipped, install skid plates. Refer to «PLATE, SKID, TRANSMISSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
11. Lower vehicle.
12. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.

Scheme 21

All engines use a stainless steel muffler and tailpipe assembly to control exhaust noise levels and exhaust back pressure. The 3.6L and 5.7L muffler and resonator/tailpipe are a one piece assembly.

On the 5.7L tailpipe. The left side resonator can be serviced separately.

Scheme 22

1. Raise the vehicle.
2. Saturate the bolts and nuts (2) with heat valve lubricant. Allow 5 minutes for penetration.
3. If equipped, remove skid plates. Refer to «PLATE, SKID, TRANSMISSION , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , REMOVAL»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
4. Remove the front exhaust pipe/catalytic converter to muffler/tailpipe (1) assembly flange (2) nuts.
5. Remove ground straps (3). NOTE: Muffler removal is a two-man operation. Never allow the muffler to hang from the isolators. A helper is required so no damage will come to the isolators or to the tailpipe/muffler assembly.
6. Remove tailpipe/muffler assembly (3) from Isolators (2).
7. Remove the muffler/tailpipe assembly from vehicle.

3.6L/5.7L ENGINE

Note. Muffler installation is a two-man operation. Never allow the muffler to hang from the isolators. A helper is required so no damage will come to the isolators or to the tailpipe/muffler assembly.

1. Position muffler and tailpipe (3) assembly in vehicle.
2. Install insulators (2).
3. Install bolts and nuts at front exhaust pipe/catalytic converter flange (2).
4. Make sure the muffler/tailpipe assembly is correctly positioned and the properly aligned. The minimum clearance between components is 25mm (1 inch).
5. Tighten nuts (2) to 47 N.m (35 ft. lbs.).
6. Install the ground strap (3).
7. If equipped, install skid plates. Refer to «PLATE, SKID, TRANSMISSION , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) or «PLATE, SKID, TRANSFER CASE , INSTALLATION»(/jeep/grand-cherokee/wk2-2010-2013/remont/frames-subframes-crossmembers/#frame-and-bumpers) .
8. Lower the vehicle.
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

3.6/5.7L ENGINE

Note. Assistance in removal is recommended. Never allow the muffler to hang from the isolators this may cause damage to either the isolators or the tailpipe/muffler assembly.

1. Raise the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove rear tailpipe isolators (2).
4. Remove the tailpipe/resonator to muffler assembly flange (2) nuts.
5. Remove tailpipe/resonator and muffler as an assembly from vehicle.

Note. Muffler installation is a two-man operation. Never allow the muffler to hang from the isolators. A helper is required so no damage will come to the isolators or to the tailpipe/muffler assembly.

1. Position the tailpipe/resonator/muffler (3) assembly in vehicle.
2. Install tailpipe/resonator insulators (2).
3. Install muffler insulators (4) and ground straps (3)
4. Align muffler (1) to the catalytic convertor pipe flange. Install and Tighten flange (2) nuts to 47 N.m (35 ft. lbs.).
5. Make sure the tailpipe/resonator assembly is correctly positioned and the properly aligned. The minimum clearance between components is 25mm (1 inch).
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.

See also:
• MANIFOLD, EXHAUST , REMOVAL , 5.7L
• SILENCER, COWL EXTENSION , REMOVAL
• PLATE, SKID, TRANSMISSION , REMOVAL
• JACKING AND HOISTING LIFT POINTS
• SPECIFICATIONS
• MUFFLER, EXHAUST , REMOVAL