Dodge Durango (DN). Manual — part 5
TAILPIPE
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) Disconnect tailpipe from rear hanger bracket
(Fig. 11).
(4) Remove muffler to tailpipe exhaust clamp (Fig. 11).
(5) Heat connection with an oxygen/acetylene torch
and twist tailpipe out of muffler.
INSTALLATION
(1) Install tailpipe to muffler. Install exhaust
clamp and start nuts by hand.
(2) Connect tailpipe hanger.
(3) Align tailpipe and tighten exhaust clamp nuts
to 42 N·m (31 ft. lbs.).
(4) Lower vehicle and connect battery negative cable.
(5) Start engine and check for exhaust leaks.
HEAT SHIELDS
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the screws and nuts holding the heat
shields to the frame and floor pan (Fig. 12) (Fig. 13)
(Fig. 14). When removing muffler heat shield, the
muffler front and rear support hangers must be
removed first (Fig. 15). Be sure to disconnect both
oxygen sensor connectors.
(3) Slide the shield out around the exhaust system.
INSTALLATION
(1) Position the heat shields to the floor pan or the
frame and install the screws and nuts.
(2) Tighten the screws/nuts to 7 N·m (60 in. lbs.)
torque. Tighten the muffler hangers to 23 N·m (200
in. lbs.)
(3) Lower the vehicle.
Fig. 10 Muffler Removal/Installation
1 – CATALYTIC CONVERTER WITH PIPE
2 – REAR MUFFLER HANGER
3 – MUFFLER
4 – CLAMP
Fig. 11 Tailipipe Removal/Installation
1 – MUFFLER
2 – TAILPIPE HANGER INSULATOR
3 – TAILPIPE HANGER
4 – TAILPIPE
5 – CLAMP
11 - 6
EXHAUST SYSTEM
DN
REMOVAL AND INSTALLATION (Continued)
Fig. 12 Front and Rear Floor Pan/Converter Shields
1 – REAR FLOOR PAN/CONVERTER SHIELD
2 – FRONT FLOOR PAN/CONVERTER SHIELD
Fig. 13 Rear Compartment/Tailpipe Heat Shield
1 – REAR COMPARTMENT TAILPIPE SHIELD
Fig. 14 Left and Right Dash Heat Shield
1 – LEFT DASH HEAT SHIELD
2 – RIGHT DASH HEAT SHIELD
Fig. 15 Muffler Heat Shield
1 – MUFFLER HEAT SHIELD
2 – MUFFLER HANGERS
DN
EXHAUST SYSTEM
11 - 7
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft.
In.
Lbs.
Lbs.
Exhaust Clamp—Nuts (All)
42
31
—
Exhaust Pipe to Manifold—
Nuts
34
25
—
Heat Shield—Nuts
7
—
60
Muffler Hanger—Bolts
23
—
200
Tailpipe Hanger—Bolt
23
—
200
11 - 8
EXHAUST SYSTEM
DN
FRAME AND BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BUMPERS
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
REMOVAL AND INSTALLATION
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT BUMPER INNER BRACKET. . . . . . . . . . . . 2
FRONT BUMPER FASCIA . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER FASCIA . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION AND OPERATION
BUMPERS
DESCRIPTION
Bumpers are used at the front and rear of the
vehicle. Bumpers are incorporated into the design of
the front and rear fascias. They are mounted to the
frame with brackets and may contain some lamp ele-
ments.
OPERATION
Bumpers are designed to protect the exterior sheet-
metal in low impact situations. The bumpers are
attached to the frame and provide mounting points
for some optional accessories such as fog lights.
REMOVAL AND INSTALLATION
FRONT BUMPER
REMOVAL
(1) Open hood.
(2) Support front bumper on a suitable lifting
device.
(3) Disengage wire connectors from fog lamps, if
equipped.
(4) Disengage
push-in
fasteners
attaching
air
deflector to bottom of bumper fascia.
(5) Pull the front wheelhouse liner back at the
bumper and remove bolts attaching outer bumper
brackets to frame rail (Fig. 1).
(6) Remove the bolts attaching the bumper to the
inner bumper bracket.
(7) Separate front bumper with outer bracket
attached from vehicle.
INSTALLATION
When the front bumper is installed, there should
be a 19 mm gap between the bumper and front
fender.
(1) Place the bumper on a suitable lifting device
and position the bumper at the vehicle.
(2) Install the bolts attaching front bumper to
inner bumper bracket. Tighten to 94 N·m (70 ft. lbs.)
torque.
(3) Install the bolts attaching outer bumper brack-
ets to the frame rail. Tighten to 94 N·m (70 ft. lbs.)
torque. Ensure front wheelhouse liners are positioned
correctly behind bumper.
(4) Engage
wire
connectors
to
fog
lamps,
if
equipped.
(5) Install push-in fasteners attaching air deflector
to front bumper fascia.
(6) Remove lifting device.
(7) Close hood.
DN
FRAME AND BUMPERS
13 - 1
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