Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 7
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
page
GENERAL INFORMATION
. . . . . . . . . . . . . . . . . . 1
SERVICE PROCEDURES
. . . . . . . . . . . . . . . . . . . 4
TORQUE SPECIFICATION
. . . . . . . . . . . . . . . . . 17
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of this
service manual.
EXHAUST SYSTEMS
The exhaust systems are produced in several con-
figurations, depending on engine and vehicle (Fig. 1).
All wheel drive vehicles have underfloor catalytic con-
verters, front wheel drive vehicles require front
mounted catalytic converters. Tail pipes, mufflers, and
resonators
are
sized
and
tuned
to
each
vehicle/powertrain combination (Fig. 1).
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on any
Chrysler catalytic converter. If damaged, the converter
must be replaced.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies, ex-
treme care should be taken with replacement parts.
There are internal converter differences required in
some parts of the country (particularly California
vehicles).
Fig. 1 Exhaust System—All Vehicles
.
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 1
SPECIAL EXHAUST BALL-JOINT COUPLING
A special exhaust ball-joint coupling (Fig. 2) is used
to secure the exhaust pipe to the engine manifold. This
living joint actually moves back and forth as the engine
moves, preventing breakage that could occur from the
back-and-forth motion of a transverse mounted engine.
The exhaust ball joint has two bolts, two springs, and
a ball joint seal ring that is a separate part from the
exhaust pipe.
EXHAUST GAS RECIRCULATION (EGR)
To assist in the control of oxides of nitrogen (NOx) in
engine exhaust, all engines are equipped with an
exhaust gas recirculation system. The use of exhaust
gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
Exhaust gases are taken from opening in the exhaust
manifold
passage
to
the
intake
manifold.
REFER
TO
SECTION
25
FOR A COMPLETE
DESCRIPTION,
DIAGNOSIS
AND
SERVICE
PROCEDURES ON THE EXHAUST GAS RECIRCU-
LATION SYSTEM AND COMPONENTS.
HEAT SHIELDS
Heat shields (Fig. 3) are needed to protect both the
vehicle and the environment from the high tempera-
tures developed near the catalytic converters.
See Body and Sheet Metal, Group 23 for service
procedures.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system
floor
pan
heat
shields
on
cars
so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and ob-
jectionable fumes.
Fig. 2 Ball-Joint Connection
Fig. 3 Heat Shields
11 - 2
EXHAUST SYSTEM AND INTAKE MANIFOLD
.
The combustion reaction caused by the catalyst re-
leases additional heat in the exhaust system. Causing
temperature increases in the area of the reactor under
severe operating conditions. Such conditions can exist
when the engine misfires or otherwise does not operate
at peak efficiency. Do not remove spark plug wires
from plugs or by any other means short out cylinders if
exhaust system is equipped with catalytic converter.
Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel pass-
ing through the converter.
The use of the catalysts also involves some non-
automotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core. Do not allow
engine to operate at fast idle for extended periods (over
5 minutes). This condition may result in excessive
exhaust system and floor pan temperatures.
EXHAUST SYSTEM DIAGNOSIS
.
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 3
SERVICE
PROCEDURES
EXHAUST PIPES, MUFFLERS AND TAILPIPES
REMOVAL
(1) Raise vehicle on hoist and apply penetrating oil
to clamp bolts and nuts of component being removed.
(2) Remove clamps and supports (Figs. 4, 5, and 6)
from exhaust system to permit alignment of parts
during assembly.
(3) When removing tailpipe, raise rear of vehicle to
relieve body weight from rear springs to provide clear-
ance between pipe and rear axle parts.
(4) Clean ends of pipes or muffler to assure mating of
all parts. Discard broken or worn insulators, rusted
clamps, supports and attaching parts.
When replacement is required on any compo-
nent of the exhaust system. It is important that
original equipment parts (or their equivalent) be
used;
• To insure proper alignment with other parts in the
system.
• Provide acceptable exhaust noise levels and does not
change exhaust system back pressure that could effect
emissions and performance.
INSTALLATION
(1) Assemble pipes, muffler supports and clamps
loosely to permit alignment of all parts.
(2) Beginning at front of system, align and clamp
each component to maintain position and proper clear-
ance with underbody parts.
(3) Tighten all clamps and supports to the proper
torques and clearances.
INTAKE AND EXHAUST MANIFOLDS—TBI ENGINE
INTAKE MANIFOLDS:
Naturally Aspirated Die-cast aluminum long-
branch fan design with remote plenum. The throttle
body is installed on the upper plenum of the manifold.
EXHAUST MANIFOLDS:
All high strength iron casting that intermesh with
the intake manifold. For standard engines a four
branch design collects and directs exhaust gases to the
conical (articulated joint connection) outlet.
THROTTLE BODY AIR HEATER
The throttle body air heater (Fig. 7) is attached to the
exhaust manifold and is removable.
Inspect air heater connector tube; replace if dam-
aged. Refer to Emission Control Systems, Group 25, for
diagnostic and service procedures on the air control
valve and temperature sensor located in the air
cleaner.
Fig. 4 Exhaust (Converter/Resonator) Pipe to Muffler
Fig. 5 Muffler to Tail Pipe
Fig. 6 Rear Tail Pipe Bracket and Insulator
11 - 4
EXHAUST SYSTEM AND INTAKE MANIFOLD
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