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Exhaust System

Engine, Cooling and Exhaust › Exhaust System
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Exhaust System: Specificationsreference
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SPECIFICATIONS
Checking The Exhaust System For Leaks12 steps
⚠ WARNING
The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has 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 operating time.
△ CAUTION
The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can occur.
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  1. Turn the ignition off.
  2. Raise the vehicle.
  3. Connect Exhaust Cone or to Air Pressure Regulator (with hose) W-18-MIL-1146AS.
  4. Attach shop air to the air pressure regulator.
  5. Adjust the Air Pressure Regulator to 27.6 kPa (4 psi)
  6. Insert the exhaust cone into the vehicle tail pipe.
  7. If the vehicle is equipped with dual exhaust. Use the with equipped attached plug, plug one side of the dual exhaust pipe. Pressurize the other as described above.
  8. Apply Mopar(R) Air Leak Detector PN 05191804AA (or an equivalent leak finder liquid) to the following areas: -All welded joints from the exhaust manifold to 152.4 mm (6 inches) behind the downstream O2 sensor -O2 sensor seal points -O2 sensor boss welds -Flange/joint connection(s) -Exhaust manifold to cylinder head connection(s) -EGR solenoid gasket base and tube seal points (if equipped)
  9. Watch for the Mopar(R) Air Leak Detector PN 05191804AA (or the equivalent leak finder liquid) to bubble.
  10. Use the following definitions to help determine if system or component repair/replacement is necessary: -Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (0.04 of an inch) or less appear. Any Type 1 or greater leaks found in welded joints, O2 sensor seal points or O2 sensor boss welds must be repaired or the component must be replaced. -Type 2 Leak is defined as a leak where larger bubbles pea size, 8 mm (0.3 of an inch) or greater appear. Any Type 2 or greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must be repaired or the components must be replaced.
  11. If a leak is found that matches the above definition, repair or replace the component as necessary.
  12. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired. Were any exhaust leaks found? Yes -Repair or replace the leaking exhaust parts as necessary. -Perform the POWERTRAIN VERIFICATION TEST. Powertrain Verification Test. No -Test complete.
Gas Enginereference
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GAS ENGINE
Exhaust System: Description and Operationreference
△ CAUTION
Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
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GAS ENGINE The basic exhaust system consists of an exhaust pipe assembly with catalytic converters (2), muffler (4) and tailpipe assembly and heat shields The exhaust system must be properly aligned to prevent stress, leakage and body contact. Minimum clearance between any exhaust component and the body or frame is 25 mm (1.0 in.). If the system contacts any body panel, it may amplify objectionable noises from the engine or body. When inspecting an exhaust system, critically inspect for cracked or loose joints, stripped screw or bolt threads, corrosion damage and worn, cracked or broken hangers. Replace all components that are badly corroded or damaged. DO NOT attempt to repair. When replacement is required, use original equipment parts (or equivalent). This will assure proper engine function and system alignment.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
DESCRIPTION-2.8L DIESEL📷 1
1 - OXYGEN SENSOR 2 - MANIVERTER 3 - MANIVERTER TO EXHAUST PIPE FLANGE 4 - FLEXIBLE BELLOWS 5 - ISOLATORS 6 - MUFFLER/TAILPIPE ASSEMBLY 7 - EXHAUST PIPE TO MUFFLER FLANGE
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
The diesel engine exhaust system consists of an engine exhaust manifold, turbocharger, EGR valve with intercooler, front exhaust pipe with catalytic converter, muffler and tailpipe assembly.
1 - MANIVERTER 2 - MANIVERTER TO DFP FLANGE 3 - PRESSURE SENSOR TUBING 4 - STEADY MOUNT 5 - FLEXIBLE BELLOWS 6 - ISOLATOR 7 - MUFFLER/TAIL PIPE ASSEMBLY 8 - DPF TO MUFFLER FLANGE
The exhaust system must be properly aligned to prevent stress, leakage and body contact. The exhaust components should be kept a minimum of 25.4 mm (1.0 in.) away from the body and frame. If the system contacts any body panel, it may amplify objectionable noises from the engine or body.
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DESCRIPTION-GAS ENGINE📷 2
1 - EXHAUST FLANGE 2 - CATALYTIC CONVERTER 3 - FRONT EXHAUST PIPE ASSEMBLY-TO-MUFFLER CLAMP 4 - MUFFLER 5 - INSULATOR 6 - RESONATOR
The basic exhaust system consists of an exhaust pipe assembly with catalytic converters (2), muffler (4) and tailpipe assembly and heat shields
The exhaust system must be properly aligned to prevent stress, leakage and body contact. Minimum clearance between any exhaust component and the body or frame is 25 mm (1.0 in.). If the system contacts any body panel, it may amplify objectionable noises from the engine or body.
When inspecting an exhaust system, critically inspect for cracked or loose joints, stripped screw or bolt threads, corrosion damage and worn, cracked or broken hangers. Replace all components that are badly corroded or damaged. DO NOT attempt to repair.
When replacement is required, use original equipment parts (or equivalent). This will assure proper engine function and system alignment.
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.
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EXHAUST SYSTEM-DIESEL ENGINE
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.
SHIELDS-HEAT📷 1

Description

1 - REAR FLOOR PAN HEAT SHIELD 2 - HEAT SHIELD RETAINING NUTS 3 - FRONT FLOOR PAN HEAT SHIELD
Heat shields (1) (3) are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. See Fig. 12.
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