Dodge Exhaust SRM 2006 Service Manual
DR EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES ...............................2
5.9L DIESEL .................................3
DIAGNOSIS AND TESTING
GAS ENGINE ................................4
DIESEL ENGINE .............................5
SPECIFICATIONS
TORQUE ....................................5
SPECIAL TOOLS ...............................7
CONVERTER-CATALYTIC
DESCRIPTION .................................8
OPERATION ...................................8
REMOVAL
3.7L/4.7L ENGINE ............................8
5.7L ENGINE ................................9
5.9L DIESEL ENGINE .........................9
8.3L ENGINE ...............................10
INSPECTION .................................10
INSTALLATION
3.7L/4.7L ENGINE ...........................10
5.7L ENGINE ...............................11
5.9L ENGINE DIESEL ........................11
8.3L ENGINE ...............................12
PIPE EXHAUST
REMOVAL
3.7L/4.7L/5.7L ENGINE ......................13
5.9L DIESEL ................................13
8.3L ENGINE ...............................13
INSPECTION .................................14
INSTALLATION
3.7L/4.7L/5.7L ENGINE ......................14
5.9L DIESEL ................................14
8.3L ENGINE ...............................15
HEAT SHIELDS
DESCRIPTION ................................16
REMOVAL ....................................16
INSTALLATION ...............................17
MUFFLER
REMOVAL
3.7L/4.7L/5.7L ENGINE ......................19
8.3L ENGINE ...............................19
5.9L DIESEL ENGINE .......................20
INSTALLATION
3.7L/4.7L/5.7L ENGINE ......................20
8.3L ENGINE ...............................21
5.9L DIESEL ENGINE .......................21
TAILPIPE
REMOVAL
3.7L/4.7L/5.7L ENGINE ......................22
5.9L DIESEL ................................22
8.3L ENGINE ...............................23
INSPECTION .................................23
INSTALLATION
3.7L/4.7L/5.7L ENGINE ......................23
5.9L DIESEL ................................24
8.3L ENGINE ...............................24
TURBOCHARGER SYSTEM
DIAGNOSIS AND TESTING
TURBOCHARGER BOOST PRESSURE .......25
TURBOCHARGER
DESCRIPTION ................................26
OPERATION ..................................27
REMOVAL
TURBOCHARGER ..........................29
TURBOCHARGER OIL DRAIN TUBE ..........30
CLEANING ...................................30
INSPECTION .................................30
INSTALLATION
TURBOCHARGER ..........................31
TURBOCHARGER OIL DRAIN TUBE ..........32
WASTEGATE - ELECTRONIC ACTUATOR
REMOVAL ....................................33
INSTALLATION ...............................33
CHARGE AIR COOLER AND PLUMBING
DESCRIPTION ................................34
OPERATION ..................................34
DIAGNOSIS AND TESTING
CHARGE AIR COOLER SYSTEM - LEAKS ....35
REMOVAL ....................................35
CLEANING ...................................36
INSPECTION .................................36
INSTALLATION ...............................36
11 - 2 EXHAUST SYSTEM DR
EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES
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 federal gasoline engine exhaust system consists of engine exhaust manifolds, exhaust pipes, catalytic converter(s), extension pipe (if needed), exhaust heat shields, muffler and exhaust tailpipe ,.
The California emission vehicles exhaust system also contains the above components as well as mini catalytic converters added to the exhaust pipe.
DR EXHAUST SYSTEM 11 - 3
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 25.4 mm (1.0 in.). If the system contacts any body panel,
it may amplify objectionable noises from the engine or body.
5.9L DIESEL
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, exhaust pipe, resonator,
extension pipe, catalytic converter, muffler and exhaust tailpipe.
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.
11 - 4 EXHAUST SYSTEM DR
DIAGNOSIS AND TESTING
GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
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.
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.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Catalytic converter rusted or
blown out.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching
nuts/bolts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Replace catalytic converter assy.
Replace restricted part if necessary.
DR EXHAUST SYSTEM 11 - 5
DIESEL ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
SPECIFICATIONS
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.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Turbocharger mounting flange
cracked.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
3. Replace exhaust pipe.
4. Tighten/replace flange attaching
nuts/bolts.
5. Replace exhaust manifold.
6. Tighten exhaust manifold to
cylinder head bolts. Replace gasket
if necessary.
7. Remove turbocharger and
inspect. (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER
SYSTEM/TURBOCHARGER REMOVAL).
Replace restricted part if necessary.
TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Bolt-Adjusting Strap 23 - 200
Nuts-Air Heater Power Supply 14 - 124
Bolts-Air Inlet Housing 24 18 Nuts-Cab Heater Supply/Return Line 24 18 Nuts-Exhaust Clamp 54 40 Bolts-Exhaust Manifold to Cylinder Head - (Diesel) 43 32 Bolts-Exhaust Manifold to Cylinder Head - (Diesel) 31 23 Bolts-Exhaust Manifold to Cylinder Head-(8.3L) 22 - 195
Bolts-Exhaust Pipe to Manifold 31 23 Bolts-Generator Mounting 41 30 Bolts-Charge Air Cooler Mounting 10 - 90
Nuts-Charge Air Cooler Duct 11 - 95
Bolt-Generator to Block-Diesel 24 18 Nuts and Bolts-Heat Shield 11 - 95
Nuts-Heat Shield-Diesel 24 18 Electronically Controlled Wastegate Command Valve-(Diesel) 34 25 Turbocharger flange studs-(Diesel) 24 18 Nuts-Turbocharger Mounting-(Diesel) 43 32 -
11 - 6 EXHAUST SYSTEM DR
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Bolts-Turbocharger Oil Drain Tube-(Diesel) 24 18 Fitting-Turbocharger Oil Supply Line-(Diesel) 36 27 Nut-Turbocharger V-Band Clamp Cast Elbow to Turbocharger-
(Diesel)
Nut-T-bolt Clamp Cast Elbow to Exhaust pipe-(Diesel) NOTE:
This is a One Time Use Only Nut.
Turbocharger Oil Supply fitting at Turbocharger-(Diesel) 36 27 Turbocharger Oil Supply fitting at lube filter head-(Diesel) 24 18 -
8-75
11 - 100
DR EXHAUST SYSTEM 11 - 7
SPECIAL TOOLS
TURBOCHARGER TESTER 9022
11 - 8 EXHAUST SYSTEM DR
CONVERTER-CATALYTIC
DESCRIPTION
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.
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 mini catalytic converters located after the exhaust manifolds and before
the inline catalytic converter.
OPERATION
The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the
exhaust stroke of the engine. This process aids in reducing emissions output.
REMOVAL
3.7L/4.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamp (4).
5. Remove bolts exhaust to manifold (2).
6. Remove catalytic converter (3).
DR EXHAUST SYSTEM 11 - 9
5.7L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove clamps and nuts (4).
5. Remove catalytic converter to exhaust manifold
bolts (2) and nuts (1).
6. Remove catalytic converter assembly (3).
5.9L DIESEL ENGINE
WARNING: IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
1. Raise and support the vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Remove clamp bolts from exhaust pipe to catalytic
converter clamp (5).
NOTE: Do not remove nut from T-Bolt. Only
remove nut far enough, so that the T-end can be
removed from the clamp.
NOTE: The catalytic converter to exhaust manifold
clamp is not reusable. Always use a new clamp
when reinstalling the catalytic converter.
4. Loosen the nut from clamp (1) at turbocharger.
5. Remove the T-bolt end of the fastener, from the
clamp (1).
6. Spread the clamp, and remove the catalytic converter (4) and front exhaust pipe (2) from the vehicle.
7. Discard the clamp.
8. Remove front exhaust pipe to catalytic converter clamp (3).
9. Separate front exhaust pipe (2) from catalytic converter (4).
11 - 10 EXHAUST SYSTEM DR
8.3L ENGINE
1. Raise and support vehicle.
2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration.
3. Disconnect oxygen sensor electrical connectors.
4. Remove LH exhaust pipe to manifold bolts (2),
retainers and nuts (1).
5. Remove LH catalytic converter to muffler clamp
nuts (4).
6. Rotate LH catalytic converters (6) from the muffler
(5).
7. Remove RH exhaust pipe to manifold bolts (2),
retainers and nuts (1).
8. Remove RH catalytic converter to muffler clamp
nuts (4).
9. Rotate RH catalytic converter (3) from the muffler
(5).
10. Remove clamps and nuts (4).
INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of
overheating. If the converter has a heat shield attached make sure it is not bent or loose.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate
a damaged core.
INSTALLATION
3.7L/4.7L ENGINE
1. Install RH catalytic converter to exhaust clamp (4)
on RH catalytic converter (3) and position into
exhaust pipe (5).
2. Install and hand tighten RH catalytic converter to
exhaust manifold bolts (2).
3. Install c-clip nut (1) and bolt (2) to converter (3) to
manifold.
4. Tighten catalytic converter to exhaust manifold
bolts (1) to 31 N·m (23 ft. lbs.).
5. Tighten all clamp nuts (4) to 52.2 N·m (40 ft. lbs.)
torque.
6. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjustments, if needed.
7. Check to ensure you have at least 25 mm clearance to oil pan.
8. Plug in O2 sensor wiring.
9. Lower the vehicle.
10. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
DR EXHAUST SYSTEM 11 - 11
5.7L ENGINE
1. Install catalytic converter to exhaust clamp (4) on
catalytic converter (3) and position into exhaust
pipe (5).
2. Make sure the alignment tang on catalytic converter (3) is fully seated in the notch on the
exhaust pipe (5).
3. Install catalytic converter to exhaust manifold bolts
(2) and nuts (1).
4. Tighten catalytic converter to exhaust manifold
bolts (2) to 31 N·m (23 ft. lbs.).
5. Tighten catalytic converter to exhaust pipe clamp
nuts (4) to 52 N·m (40 ft. lbs.) torque.
6. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components
and body/frame parts. Make the necessary adjustments, if needed.
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
5.9L ENGINE DIESEL
NOTE: The catalytic converter to Front exhaust
pipe clamp is not reusable. Always use a new
clamp when reinstalling the catalytic converter.
NOTE: The Front exhaust pipe to Elbow clamp is
not reusable. Always use a new clamp when reinstalling the Front exhaust pipe.
1. Position the catalytic converter (4) onto the front
exhaust pipe (2) until the alignment tab is seated
into the alignment slot of the catalytic converter (4).
2. Install catalytic converter (4) into the exhaust pipe
(6) until the alignment tab is seated into the alignment slot of exhaust pipe (6).
3. Position front exhaust pipe (2) onto turbocharger
and install new clamp (1). Tighten the nuts to 11
N·m (100 in. lbs.) torque.
4. Install the exhaust clamp (5) at the exhaust pipe
(6) and catalytic converter (4) connection. Tighten
the clamp nuts to 54 N·m (40 ft. lbs.) torque.
5. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is required between the exhaust system components and body/frame
parts. Make the necessary adjustments, if needed.
6. Lower the vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
11 - 12 EXHAUST SYSTEM DR
8.3L ENGINE
1. Make sure catalytic converters (3, 6) and mufflers
(5) are free of burrs.
2. Insert RH catalytic converter (3) into muffler (5).
3. Make sure the alignment tang on the catalytic converter (3) seats in the alignment slot on the muffler
(5).
4. Position the catalytic converter (3) to the exhaust
manifold. Install and hand tighten bolts (2) , retainers and nuts (1).
5. Insert LH catalytic converter (6) into muffler (5).
6. Make sure the alignment tang on the catalytic converter (6) seats in the alignment slot on the muffler
(5).
7. Position the catalytic converter (6) to the exhaust
manifold. Install and hand tighten bolts (2), retainers and nuts (1).
8. Check the exhaust system for contact with the
body panels. A minimum of 25 mm (1.0 in.) is
required between the exhaust system components and body/frame parts. Clearance between catalytic converter
and frame is 15 mm (.59 inch). Make the necessary adjustments, if needed.
9. Tighten catalytic converter to exhaust manifold bolts (2) to 20 N·m (15 ft. lbs.) torque.
10. Tighten the clamp nuts to 54 N·m (40 ft. lbs.) torque.
11. Lower the vehicle.
12. Start the engine and inspect for exhaust leaks. and exhaust system. Repair exhaust leaks as necessary.
Loading...