Dodge Nitro. Manual — part 610

EXHAUST SYSTEM-DIESEL ENGINE

EXHAUST SYSTEM DIAGNOSIS CHART

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.

CAUTION:

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.

CAUTION: On high mileage vehicles it is normal to see some exhaust staining around

the turbocharger control rod area. This is not a sign of turbocharger
failure.

CONDITION

POSSIBLE CAUSE

CORRECTION

EXCESSIVE EXHAUST NOISE

OR LEAKING EXHAUST

GASES

1. Leaks at pipe joints.

1. Tighten clamps/bolts 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. Replace
gasket if necessary.

7. Turbocharger mounting flange
cracked.

7. Remove turbocharger and
inspect. (Refer to REMOVAL ).

8. Restriction in exhaust system.

8. Remove restriction, if possible.
Replace restricted part if
necessary.

9. EGR pipe(s) leak.

9. Tighten bolts. Replace gasket.

10. EGR assembly leak.

10. Tighten bolts. Replace gaskets.

Driveability Concern - Turbo

1. Vacuum hose disconnected.

1. Check connections, replace as
necessary.

2. Vacuum system leaks.

2. Inspect for damage. Check for

2007 Dodge Nitro R/T

2007 ENGINE Exhaust System And Turbocharger - Nitro

SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

SPECIAL TOOLS

SPECIAL TOOLS

Fig. 4: Turbocharger Tester 9022
Courtesy of CHRYSLER LLC

leaks, replace as necessary.

3. Boost pressure solenoid filter
clogged.

3. Replace the filter.

DESCRIPTION

N.m

Ft. Lbs.

In. Lbs.

EGR Pipe to EGR Inlet

32

24

-

Front Exhaust Pipe

Flange-to-Exhaust

Manifold Bolts

36

28

-

Front Exhaust pipe-to-

Muffler Flange Nuts

36

28

-

Turbocharger Support

Bracket Bolts

24

18

-

Turbocharger Downpipe

Nuts

32

24

-

Turbocharger Oil Supply

Line Fitting

24

18

215

Turbocharger Oil Return

Line bolts

11

-

96

Turbocharger to Exhaust

Manifold Nuts

32

24

-

2007 Dodge Nitro R/T

2007 ENGINE Exhaust System And Turbocharger - Nitro

Fig. 5: Adaptor 8442
Courtesy of CHRYSLER LLC

CONVERTER-CATALYTIC

DESCRIPTION

DESCRIPTION

The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in
bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the
converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same
time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage.

Unleaded gasoline must be used to avoid contaminating the catalyst core.

50 State emission vehicles incorporate two catalytic converters located after the exhaust manifolds and before
the muffler.

REMOVAL

WARNING:

The normal operating temperature of the exhaust system is very high.
Therefore, never work around or attempt to service any part of the
exhaust system until it is cooled. Special care should be taken when
working near the catalytic converter. The temperature of the converter
rises to a high level after a short period of engine operation time.

CAUTION: DO NOT remove spark plug wires from plugs or by any other means short

out cylinders. Failure of the catalytic converter can occur due to a
temperature increase caused by unburned fuel passing through the
converter.

2007 Dodge Nitro R/T

2007 ENGINE Exhaust System And Turbocharger - Nitro

REMOVAL-3.7L ENGINE

Fig. 6: 3.7L Catalytic Converter
Courtesy of CHRYSLER LLC

1. Raise and support the vehicle.

2. Saturate the bolts (1) and nuts with heat valve lubricant. Allow 5 minutes for penetration.

3. Disconnect oxygen sensor electrical connectors.

4. Remove the nuts from the front exhaust pipe and catalytic converter assembly to muffler flange.

WARNING:

If torches are used when working on the exhaust system, do not allow the
flame near the fuel lines.

2007 Dodge Nitro R/T

2007 ENGINE Exhaust System And Turbocharger - Nitro