Dodge Durango (DN). Manual — part 4
CATALYTIC CONVERTER
DESCRIPTION
California emissions vehicles incorporate mini cat-
alytic converters into the exhaust system. The pipes
and catalytic converters are made of stainless steel
designed to operate at extremely high temperatures
(Fig. 2).
OPERATION
The catalytic converter captures and burns any
unburned fuel mixture exiting the combustion cham-
bers during the exhaust stroke of the engine. This
process aids in reducing emissions output.
EXHAUST PIPE
DESCRIPTION
The exhaust pipe(s) is a one piece design encom-
passing the exhaust pipe(s) and the catalytic convert-
er(s). Neither the exhaust pipe(s) or the catalytic
converter(s) is serviceable separately (Fig. 3).
MUFFLER
DESCRIPTION
All engines use a stainless steel muffler to control
exhaust noise levels and exhaust back pressure (Fig.
4).
Fig. 2 Catalytic Converter—Typical
1 – EXHAUST PIPE
2 – CONVERTER
3 – MUFFLER
4 – CLAMP
Fig. 3 Exhaust Pipe with Integral Catalytic
Converter(s)
1 – NUT
2 – EXHAUST PIPE
3 – MINI CATALYTIC CONVERTERS (CALIFORNIA EMISSIONS
VEHICLES ONLY)
4 – CATALYTIC CONVERTER
Fig. 4 Muffler—Typical
1 – CATALYTIC CONVERTER WITH PIPE
2 – REAR MUFFLER HANGER
3 – MUFFLER
4 – CLAMP
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EXHAUST SYSTEM
DN
DESCRIPTION AND OPERATION (Continued)
OPERATION
The muffler is designed to muffle the sound of the
exhaust as if leaves the engine.
TAILPIPE
DESCRIPTION
The tailpipe is made of stainless steel and attaches
to the muffler (Fig. 5).
OPERATION
The tailpipe channels the exhaust out of the muf-
fler and out from under the vehicle to control noise
and prevent exhaust gas fumes from entering the
passenger compartment.
HEAT SHIELDS
DESCRIPTION
There are two types of heat shields used. One is
stamped steel the other is molded foil sheets. The
shields attach to the vehicle around the exhaust system
(Fig. 6).
OPERATION
The heat shields prevent heat from the exhaust
system from entering the passenger area and other
areas where the heat can cause damage to other com-
ponents.
Fig. 6 Heat Shield—Typical
1 – MUFFLER HEAT SHIELD
2 – MUFFLER HANGERS
Fig. 5 Tailpipe—Typical
1 – MUFFLER
2 – TAILPIPE HANGER INSULATOR
3 – TAILPIPE HANGER
4 – TAILPIPE
5 – CLAMP
DN
EXHAUST SYSTEM
11 - 3
DESCRIPTION AND OPERATION (Continued)
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. 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.
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.
REMOVAL AND INSTALLATION
EXHAUST PIPE
CAUTION: When servicing or 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.
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with Mopar
t Rust
Penetrant. Allow 5 minutes for penetration.
(3) Disconnect the oxygen sensor(s).
(4) Remove the exhaust manifold-to-exhaust pipe
nuts (Fig. 7) (Fig. 8) (Fig. 9).
(5) Remove
exhaust
pipe/converter
to
muffler
exhaust clamp.
(6) Disconnect the exhaust pipe/catalytic converter
from muffler.
(7) Remove the exhaust pipe.
Fig. 7 Exhaust Pipe to Manifold Connection—(5.2L
and 5.9L)
1 – BOLT
2 – RETAINER
3 – EXHAUST MANIFOLD
4 – NUT
5 – EXHAUST PIPE
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EXHAUST SYSTEM
DN
INSTALLATION
(1) Align and connect the exhaust pipe/catalytic
converter to the muffler. Install exhaust clamp and
tighten clamp nuts to 42 N·m (31 ft. lbs.) torque.
(2) Connect the exhaust pipe(s) to the exhaust
manifold. Tighten the nuts to 34 N·m (25 ft. lbs.)
torque.
(3) Connect oxygen sensor connector(s).
(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.
CATALYTIC CONVERTER
NOTE: Neither the inline catalytic converter nor the
mini catalytic converters (California emission vehi-
cles only) are serviceable separately from the
exhaust pipe. Refer to Exhaust Pipe for removal /
installation procedure.
MUFFLER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, WEAR PROTEC-
TIVE EYE COVERING AND DO NOT ALLOW THE
FLAME NEAR THE FUEL LINES.
CAUTION: When servicing or replacing exhaust
system components, be sure to disconnect all oxy-
gen sensor connectors. Allowing the exhaust sys-
tem to hang by the harness will damage the wiring
and/or sensor.
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise vehicle on hoist.
(3) Remove muffler to exhaust pipe/catalytic con-
verter and tailpipe clamps (Fig. 10).
(4) Remove tailpipe from hanger isolator. Heat
muffler to tailpipe with an oxygen/acetylene torch
and twist tailpipe out of muffler.
(5) Disconnect muffler from hanger isolators (Fig.
10).
(6) Heat muffler to exhaust pipe/catalytic con-
verter connection and twist muffler off of converter
pipe.
INSTALLATION
(1) Install muffler to exhaust pipe/catalytic con-
verter and tailpipe. Install exhaust clamps and start
nuts by hand.
(2) Connect muffler to rear muffler hanger.
(3) Connect tailpipe to rear hanger.
(4) Align muffler and tighten exhaust clamp nuts
to 42 N·m (31 ft. lbs.).
(5) Lower vehicle and connect battery negative
cable.
(6) Start engine and check for exhaust leaks.
Fig. 8 Exhaust Pipe(s) to Manifold Connection—
(4.7L Federal Models)
1 – BOLT
2 – RETAINER
3 – EXHAUST MANIFOLD
4 – NUT
5 – EXHAUST PIPE
Fig. 9 Exhaust Pipe(s) to Manifold Connection—
(4.7L California Models)
1 – BOLT
2 – RETAINER
3 – EXHAUST MANIFOLD
4 – NUT
5 – EXHAUST PIPE
DN
EXHAUST SYSTEM
11 - 5
REMOVAL AND INSTALLATION (Continued)
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