Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Dodge Durango 1998-2000 Approved Dodge Durango 1998-99 98DN_11

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DN                                                                       EXHAUST SYSTEM AND INTAKE MANIFOLD                              11 - 1



                   EXHAUST SYSTEM AND INTAKE MANIFOLD
                                                             CONTENTS

                                                               page                                                                        page

GENERAL INFORMATION                                                       EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 9
  CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . .          1    EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 3
  EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .       1    HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 5
  HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . .   1    INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION AND OPERATION                                                 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
  EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . .         2    TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
  INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . .      2   CLEANING AND INSPECTION
DIAGNOSIS AND TESTING                                                     EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 11
  EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .       2    INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION                                                 SPECIFICATIONS
  CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . .          3    TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 11

GENERAL INFORMATION                                                      occur. If a converter is heat-damaged, correct the
                                                                         cause of the damage at the same time the converter
EXHAUST SYSTEM                                                           is replaced. Also, inspect all other components of the
   The basic exhaust system consists of exhaust man-                     exhaust system for heat damage.
ifold(s), exhaust pipe, catalytic converter, heat                           Unleaded gasoline must be used to avoid contami-
shield(s), muffler and tailpipe.                                         nating the catalyst core.
   The exhaust system uses a single muffler with a                          DO NOT remove spark plug wires from plugs or by
single monolithic-type catalytic converter.                              any other means short out cylinders. Failure of the
   The exhaust manifolds are equipped with ball                          catalytic converter can occur due to a temperature
flange outlets to assure a tight seal and strain free                    increase caused by unburned fuel passing through
connections.                                                             the converter.
   The exhaust system must be properly aligned to                           DO NOT allow the engine to operate at fast idle for
prevent stress, leakage and body contact. If the sys-                    extended periods (over 5 minutes). This condition
tem contacts any body panel, it may amplify objec-                       may result in excessive temperatures in the exhaust
tionable noises originating from the engine or body.                     system and on the floor pan.
   When inspecting an exhaust system, critically
inspect for cracked or loose joints, stripped screw or                   HEAT SHIELDS
bolt threads, corrosion damage and worn, cracked or                        Heat shields are needed to protect both the vehicle
broken hangers. Replace all components that are                          and the environment from the high temperatures
badly corroded or damaged. DO NOT attempt to                             developed by the catalytic converter. The catalytic
repair.                                                                  converter releases additional heat into the exhaust
   When replacement is required, use original equip-                     system. Under severe operating conditions, the tem-
ment parts (or their equivalent). This will assure                       perature increases in the area of the converter. Such
proper alignment and provide acceptable exhaust                          conditions can exist when the engine misfires or oth-
noise levels.                                                            erwise does not operate at peak efficiency.

CATALYTIC CONVERTER                                                      CAUTION: Avoid application of rust prevention
  The stainless steel catalytic converter body is                        compounds or undercoating materials to exhaust
designed to last the life of the vehicle. Excessive heat                 system floor pan heat shields. Light overspray near
can result in bulging or other distortion, but exces-                    the edges is permitted. Application of coating will
sive heat will not be the fault of the converter. If                     result in excessive floor pan temperatures and
unburned fuel enters the converter, overheating may                      objectionable fumes.
11 - 2   EXHAUST SYSTEM AND INTAKE MANIFOLD                                                                  DN


DESCRIPTION AND OPERATION                                 EXHAUST MANIFOLD
                                                            The exhaust manifolds are constructed of cast iron
INTAKE MANIFOLD                                           and are LOG type with balanced flow.
  The aluminum intake manifold is a single plane
design with equal length runners. The manifold is
sealed by flange side gaskets with front and rear
cross-over gaskets.

DIAGNOSIS AND TESTING
EXHAUST SYSTEM
                                EXHAUST SYSTEM DIAGNOSIS CHART

           CONDITION                         POSSIBLE CAUSE                           CORRECTION

EXCESSIVE EXHAUST NOISE OR           1. Leaks at pipe joints.              1. Tighten clamps/bolts at leaking
LEAKING EXHAUST GASES                                                      joints.
                                     2. Rusted or blown out muffler.       2. Replace muffler. Inspect exhaust
                                                                           system.
                                     3. Broken or rusted out exhaust       3. Replace exhaust pipe.
                                     pipe.
                                     4. Exhaust pipe leaking at manifold   4. Tighten/replace flange attaching
                                     flange.                               nuts/bolts.
                                     5. Exhaust manifold cracked or        5. Replace exhaust manifold.
                                     broken.
                                     6. Leak between exhaust manifold      6. Tighten exhaust manifold to
                                     and cylinder head.                    cylinder head bolts.
                                     7. Catalytic converter rusted or      7. Replace catalytic converter assy.
                                     blown out.
                                     8. Restriction in exhaust system.     8. Remove restriction, if possible.
                                                                           Replace restricted part if necessary.

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.
DN                                                       EXHAUST SYSTEM AND INTAKE MANIFOLD            11 - 3


REMOVAL AND INSTALLATION                                   (2) Connect exhaust pipe to catalytic converter and
                                                         install exhaust clamp. Start nuts by hand.
EXHAUST PIPE                                               (3) Align exhaust pipe and tighten exhaust pipe to
                                                         manifold nuts to 34 N



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