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.

The gasoline engine exhaust system consists of
engine exhaust manifolds, exhaust pipes (4) , catalytic
converter(s) (5), extension pipe (if needed) (6),
exhaust heat shields (7), muffler and exhaust tailpipe
(1).

The exhaust system must be properly aligned to pre-
vent stress, leakage and body contact. Minimum
clearance between any exhaust component and the
body or frame is 25.4 mm (1.0 in.). If the system con-
tacts any body panel, it may amplify objectionable
noises from the engine or body.

OPERATION

The exhaust system channels exhaust gases from the engine and away from the vehicle.

EXHAUST SYSTEM

11 - 1

DIAGNOSIS AND TESTING

EXHAUST SYSTEM

EXHAUST SYSTEM DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSE

CORRECTION

EXCESSIVE EXHAUST NOISE

1. Leaks at pipe joints.

1. Tighten clamps to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).

2. Burned or blown out muffler.

2. Replace muffler assembly (Refer
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.

3. Burned or rusted-out exhaust
pipe.

3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).

4. Exhaust pipe leaking at manifold
flange.

4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).

5. Exhaust manifold cracked or
broken.

5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).

6. Leak between exhaust manifold
and cylinder head.

6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).

7. Restriction in muffler or tailpipe.

7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.

8. Exhaust system contacting body
or chassis.

8. Re-align exhaust system to clear
surrounding components.

LEAKING EXHAUST GASES

1. Leaks at pipe joints.

1. Tighten/replace clamps at leaking
joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).

SPECIFICATIONS

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Exhaust Clamp Nuts (All)

Exhaust Pipe to Manifold Nuts

Heat Shield Nuts

Muffler Hanger Bolts

200

Tailpipe Hanger Bolt

200

11 - 2

EXHAUST SYSTEM

CONVERTER-CATALYTIC

DESCRIPTION

California emissions vehicles incorporate mini catalytic converters into the exhaust system. These catalytic convert-
ers are made of stainless steel designed to operate at extremely high temperatures.

OPERATION

The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the
exhaust stroke of the engine. This process aids in reducing emissions output.

REMOVAL

3.7L/4.7L ENGINE

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

1. Raise and support the vehicle.

2. Saturate all exhaust bolts and nuts with Mopar

Rust Penetrant. Allow 5 minutes for penetration.

3. DIsconnect the oxygen senor electrical connectors.

4. Remove the catalytic converter-to-manifold bolts

(5).

5. Remove the clamp (1) holding the catalytic con-

verter (3) to the exhaust pipe(s) (2).

6. If present, grind tack weld.

7. Remove the clamp holding the catalytic converter

flange to the muffler or extension pipe.

8. Remove the catalytic converter. You may have to

loosen up other sections of the exhaust system.

EXHAUST SYSTEM

11 - 3

5.7L ENGINE

1. Raise and support the vehicle.

2. Saturate all exhaust bolts and nuts with Mopar

Rust Penetrant. Allow 5 minutes for penetration.

3. Remove the clamp (3) holding the LH catalytic con-

verter (4) to the RH catalytic converter (2).

4. If present, grind any tack welds.

5. Remove the catalytic converter-to-manifold bolts

(1).

6. Remove the LH catalytic converter (4) from the RH

catalytic converter (2).

7. Remove the clamp holding the RH catalytic con-

verter (2) to the exhaust pipe(s).

8. If present, grind tack weld.

9. Remove the RH catalytic converter (2) from the

extension pipe.

10. You may have to loosen up other sections of the

exhaust system.

INSPECTION

Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of
overheating. If the converter has a heat shield attached make sure it is not bent or loose.

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

INSTALLATION

3.7L/4.7L ENGINE

1. Make sure the catayltic converter pipe is free of

burrs.

2. Insert the catalytic converter into the exhaust pipe.

3. Make sure the alignment tang is fully seated in the

alignment slot.

4. If other sections of the exhaust system where loos-

ened in removal, refer to that information for the
tightening procedures.

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EXHAUST SYSTEM

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