Dodge Dakota (R1). Manual — part 550
INSTALLATION
(1)
Position the heat shields to the floor pan or
the frame and install the screws and/or nuts.
(2) Tighten the nuts and/or screws to specification.
Refer to Specifications in this section for correct
torque values.
(3) Lower the vehicle.
INTERMEDIATE PIPE
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with Mopar
t Rust
Penetrant. Allow 5 minutes for penetration.
(3) Remove the front and rear clamp nuts.
(4) It may be necessary to loosen other sections of
the exhaust system to remove the extension pipe.
INSTALLATION
(1) Position the extension pipe in the muffler and
the catalytic converter flange.
(2) If other sections of the exhaust system where
loosened in removal, refer to the section for tighten-
ing procedures.
(3) Install the clamps and nuts (Fig. 4). Tighten
the nuts to 47 N·m (35 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine, inspect for exhaust leaks and
exhaust system contact with the body panels. Adjust
the alignment, if needed.
MUFFLER
DESCRIPTION
All engines use a stainless steel muffler to control
exhaust noise levels and exhaust back pressure.
REMOVAL
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.
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with Mopar
t Rust
Penetrant. Allow 5 minutes for penetration.
(3) Remove the muffler clamp nuts from the front
hanger and the rear muffler to tailpipe connection
(Fig. 23).
(4) Disconnect the muffler from the tailpipe. The
tailpipe should be supported when the muffler is dis-
connected.
(5) Remove the muffler from the extension pipe or
catalytic converter flange.
Fig. 21 Electrical Connector Heat Shield—45RFE
Transmission
1 - BOLT RETAINER
2 - LOCKNUT
3 - STUDS
4 - HEAT SHIELD
Fig. 22 Muffler Heat Shield—4 Door Cab
1 - SCREW SELF TAPPING
2 - MUFFLER HEAT SHIELD
3 - SCREW SELF TAPPING
4 - ISOLATOR
5 - HANGER BRACKET
11 - 12
EXHAUST SYSTEM
AN
HEAT SHIELDS (Continued)
INSTALLATION
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.
(1) If the upper front muffler support was removed
(Fig. 23), install the bolts into the frame. Tighten the
bolts to 23 N·m (200 in. lbs.) torque. The insulators
slip over the ends of the upper and lower muffler
hangers.
(2) Install the muffler into the extension pipe or
catalytic converter flange. Install the clamp and
tighten the nuts finger tight.
(3) Install the tailpipe into the rear of the muffler.
(4) Tighten the clamp nuts on the front and rear
muffler hangers to 41 N·m (30 ft. lbs.) torque.
(5) Lower the vehicle.
(6) Start the engine, inspect for exhaust leaks and
exhaust system contact with the body panels. Adjust
the alignment, if needed.
TAILPIPE - 2.5L/3.9L/4.7L
DESCRIPTION
The tailpipe is made of stainless steel and attaches
to the muffler.
REMOVAL
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.
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with Mopar
t Rust
Penetrant. Allow 5 minutes for penetration.
(3) Remove muffler to tailpipe exhaust clamp.
(4) Remove the tailpipe from the front and rear
insulators (Fig. 24).
(5) Remove the tailpipe.
Fig. 23 Muffler and Tailpipe Assembly
1 - TAILPIPE HANGER
2 - MUFFLER AND TAILPIPE
3 - FRONT MUFFLER HANGER
4 - REAR MUFFLER HANGER
Fig. 24 Tailpipe and Hangers—2.5L/3.9L/4.7L
1 - INSULATORS
2 - TAILPIPE
3 - CLAMP
4 - MUFFLER
AN
EXHAUST SYSTEM
11 - 13
MUFFLER (Continued)
INSTALLATION
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.
(1) Position the tailpipe into the muffler. Install
the nuts onto the clamp bolt finger tight.
(2) Install the tailpipe into the insulators.
(3) Position tailpipe and tighten the muffler rear
clamp nuts to 47 N·m (35 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine, inspect for exhaust leaks and
exhaust system contact with the body panels. Adjust
the alignment, if needed.
TAILPIPE - 5.9L
DESCRIPTION
The tailpipe is made of stainless steel and attaches
to the muffler.
REMOVAL
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.
(1) Raise and support the vehicle.
(2) Saturate the clamp nuts with Mopar
t Rust
Penetrant. Allow 5 minutes for penetration.
(3) Remove muffler to tailpipe exhaust clamp.
(4) Remove the tailpipe from the front and rear
insulators (Fig. 25).
(5) Remove the tailpipe.
INSTALLATION
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.
(1) Position the tailpipe into the muffler. Install
the nuts onto the clamp bolt finger tight.
(2) Install the tailpipe into the insulators.
(3) Position tailpipe and tighten the muffler rear
clamp nuts to 47 N·m (35 ft. lbs.) torque.
(4) Lower the vehicle.
(5) Start the engine, inspect for exhaust leaks and
exhaust system contact with the body panels. Adjust
the alignment, if needed.
Fig. 25 Tailpipe and Hangers—5.9L R/T
1 - HANGER BRACKETS
2 - ISOLATOR
3 - TAILPIPE
11 - 14
EXHAUST SYSTEM
AN
TAILPIPE - 2.5L/3.9L/4.7L (Continued)
EXHAUST SYSTEM AND TURBOCHARGER
TABLE OF CONTENTS
page
page
EXHAUST SYSTEM AND TURBOCHARGER
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
TURBOCHARGER SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EXHAUST MANIFOLD AND TURBOCHARGER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHARGE AIR COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXHAUST SYSTEM AND
TURBOCHARGER
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
Torque
EGR Attaching Bolts
27 N·m
EGR Tube Nut
34 N·m
EGR Tube Flange Bolts
27 N·m
Exhaust Manifold
Nuts
32 N·m
Exhaust Manifold
Heat Shield Bolts
11 N·m
Exhaust Pipe Support
Clamp Bolts
22.5 N·m
Exhaust Pipe Support
Clamp Screw
22.5 N·m
Intake Elbow to Intake
Manifold Bolts
11 N·m
Intake Manifold
Nuts
32 N·m
Muffler-to-Exhaust Pipe
Clamp Nuts
43 N·m
Tail Pipe Clamp
Hanger bolt
22.5 N·m
DESCRIPTION
Torque
Turbocharger-to-
Exhaust manifold
Nuts
32 N·m
Turbocharger
Oil Feed Line
27.4 N·m
Turbocharger Down
Pipe-to-Exhaust Pipe
Bolts/Nuts
22.5 N·m
Turbocharger Down
Pipe-to-Turbocharger
Bolts
27 N·m
TURBOCHARGER SYSTEM
DESCRIPTION
CAUTION: The turbocharger is a performance part
and must not be tampered with. The wastegate
bracket is an integral part of the turbocharger. Tam-
pering with the wastegate components can reduce
durability by increasing cylinder pressure and ther-
mal loading due to incorrect inlet and exhaust man-
ifold pressure. Poor fuel economy and failure to
meet regulatory emissions laws may result. Increas-
ing the turbocharger boost WILL NOT increase
engine power.
The turbocharger is an exhaust-driven super-
charger which increases the pressure and density of
the air entering the engine. With the increase of air
entering the engine, more fuel can be injected into
the cylinders, which creates more power during com-
bustion.
R1
EXHAUST SYSTEM AND TURBOCHARGER
11a - 1
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