Description-Gas Engines

Fig 1: Exhaust System - 3.7L/4.7L

Courtesy of CHRYSLER LLC

1 - FRONT EXHAUST PIPE/CATALYTIC CONVERTER ASSEMBLY

2 - STEADY REST BRACKET

3 - MUFFLER/TAILPIPE ASSEMBLY

4 - TAILPIPE HANGER REAR MOUNT INSULATOR

5 - FRONT EXHAUST PIPE/CATALYTIC CONVERTER ASSEMBLY TO MUFFLER FLANGE

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: Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in excessive floor pan temperatures and objectionable fumes.

The 3.7L/4.7L exhaust system uses two catalytic converters located in the front exhaust pipe, and a single muffler/tailpipe assembly.

Fig 2: Exhaust System - 5.7L

Courtesy of CHRYSLER LLC

1 - FRONT EXHAUST PIPE/CATALYTIC CONVERTER ASSEMBLY

2 - MUFFLER

3 - INSULATOR

4 - MUFFLER TO TAILPIPE/RESONATOR FLANGE

5 - TAILPIPE/RESONATOR ASSEMBLY

6 - FRONT EXHAUST PIPE/CATALYTIC CONVERTER ASSEMBLY TO MUFFLER FLANGE

7 - STEADY REST BRACKET

The 5.7L exhaust system uses two catalytic converters located in the front exhaust pipe, and a single muffler and tailpipe/resonator assembly.

The front exhaust pipe/catalytic converter assembly is a hydra-form thin wall air gap design. This design is used to reduce heat, noise and improve emissions. When replacement is required, use original equipment parts (or their equivalent).

The exhaust manifolds are equipped with ball flange outlets to assure a tight seal and strain free connections.

The exhaust system must be properly aligned to prevent stress, leakage and body contact. If the system contacts any body panel, it may amplify objectionable noises originating 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 their equivalent). This will assure proper alignment and provide acceptable exhaust noise levels.

The basic exhaust system consists of exhaust manifold(s), exhaust pipe with oxygen sensors, catalytic converter(s), muffler and tailpipe.