Dodge Dakota (R1). Manual — part 549
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe(s) to the exhaust
manifold. Tighten the nuts to 26 N·m (19 ft. lbs.)
torque.
(2) Align and connect the exhaust pipe to the cat-
alytic converter flange (Fig. 9). Install exhaust clamp
and tighten clamp nuts to 41 N·m (33 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.
EXHAUST PIPE - 3.9L AND
5.9L
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 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. 10).
(5) Remove exhaust pipe to converter exhaust
clamp.
(6) Disconnect the exhaust pipe from the catalytic
converter front flange.
(7) Remove the exhaust pipe.
Fig. 9 Exhaust Pipe-to-Catalytic Converter Flange
Alignment—Typical
1 - 7.874–17.526 mm (0.31–0.69 in.)
2 - CATALYTIC CONVERTER FLANGE
3 - 20 mm (0.79
9
) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
Fig. 10 Exhaust Pipe to Manifold Connection—(3.9L/
5.9L)
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - EXHAUST PIPE
11 - 8
EXHAUST SYSTEM
AN
EXHAUST PIPE - 2.5L (Continued)
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe(s) to the exhaust
manifold. Tighten the nuts to 26 N·m (19 ft. lbs.)
torque.
(2) Align and connect the exhaust pipe to the cat-
alytic converter flange (Fig. 11). Install exhaust
clamp and tighten clamp nuts to 41 N·m (33 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.
EXHAUST PIPE - 4.7L
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 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. 12).
(5) Remove exhaust pipe to converter exhaust
clamp.
(6) Disconnect the exhaust pipe from the catalytic
converter front flange.
(7) Remove the exhaust pipe.
Fig. 11 Exhaust Pipe-to-Catalytic Converter Flange
Alignment—Typical
1 - 7.874–17.526 mm (0.31–0.69 in.)
2 - CATALYTIC CONVERTER FLANGE
3 - 20 mm (0.79
9
) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
Fig. 12 Exhaust Pipe(s) to Manifold Connection - (50
State Models)
1 - BOLT
2 - RETAINER
3 - EXHAUST MANIFOLD
4 - NUT
5 - EXHAUST PIPE
AN
EXHAUST SYSTEM
11 - 9
EXHAUST PIPE - 3.9L AND 5.9L (Continued)
INSPECTION
Discard rusted clamps, broken or worn supports
and attaching parts. Replace a component with orig-
inal equipment parts, or equivalent. This will assure
proper alignment with other parts in the system and
provide acceptable exhaust noise levels.
INSTALLATION
(1) Connect the exhaust pipe(s) to the exhaust
manifold. Tighten the nuts to 26 N·m (19 ft. lbs.)
torque.
(2) Align and connect the exhaust pipe to the cat-
alytic converter flange (Fig. 13). Install exhaust
clamp and tighten clamp nuts to 41 N·m (33 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.
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 sys-
tem to prevent heat from the exhaust system from
entering the passenger area and other areas where
the heat can cause damage to other components (Fig.
14, 15, 16, 17, 18, 19, 20, 21, 22).
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the screws and/or nuts holding the
heat shields to the frame and/or floor pan.
(3) When removing muffler heat shield, the muf-
fler front support bracket must be removed first.
(4) Slide the shields out around the exhaust sys-
tem.
Fig. 14 Floor Pan Heat Shields—Standard Cab
1 - FLOOR PAN HEAT SHIELD
2 - SCREW AND WASHER SELF TAPPING
3 - NUT AND WASHER
4 - FLOOR PAN HEAT SHIELD
Fig. 15 Floor Pan Heat Shields—Extended Cab
1 - FLOOR PAN AND CATALYTIC CONVERTER HEAT SHIELD
2 - SCREW AND WASHER SELF TAPPING
3 - NUT AND WASHER
4 - FLOOR PAN HEAT SHIELD
Fig. 13 Exhaust Pipe-to-Catalytic Converter Flange
Alignment—Typical
1 - 7.874–17.526 mm (0.31–0.69 in.)
2 - CATALYTIC CONVERTER FLANGE
3 - 20 mm (0.79
9
) MIN.
4 - CROSSMEMBER
5 - EXHAUST PIPE
6 - EXHAUST PIPE
11 - 10
EXHAUST SYSTEM
AN
EXHAUST PIPE - 4.7L (Continued)
Fig. 16 Floor Pan Heat Shields, Front and Middle
Shields—4 Door Cab
1 - FLOOR PAN (FRONT) HEAT SHIELD
2 - NUT AND WASHER
3 - SELF TAPPING SCREW
4 - FLOOR PAN (MIDDLE) HEAT SHIELD
Fig. 17 Floor Pan Heat Shields Front Floor Pan
Shield—4 Door Cab
1 - FLOOR PAN (MIDDLE) HEAT SHIELD
2 - NUT AND WASHER
3 - FLOOR PAN (FRONT) HEAT SHIELD
Fig. 18 Center Bearing Heat Shield—Standard Cab
and Extended Cab
1 - SCREW AND WASHER SELF TAPPING
2 - CENTER BEARING HEAT SHIELD
Fig. 19 Dash/Floor Pan Heat Shields
1 - SCREWS
2 - NUT AND WASHER
3 - FRONT FLOOR/DASH HEAT SHIELD
Fig. 20 Tail Pipe Heat Shield
1 - TAILPIPE HEAT SHIELD
2 - FUEL TANK CROSSMEMBER
3 - SCREW AND WASHER
AN
EXHAUST SYSTEM
11 - 11
HEAT SHIELDS (Continued)
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