Exhaust Leak Testing
WARNING: This page is about a different variant/trim than selected.
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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.
- Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE
.CAUTION:
The air pressure must not exceed 4 psi, otherwise engine damage can occur.
- Connect the Truck Exhaust Cone Tool (special tool #8404-ECT, Exhaust Cone, Truck), to Air Pressure Regulator (with hose) W-18-MIL-1146AS.
- Attach shop air to the air pressure regulator.
- Adjust the air pressure regulator to 4 psi.
- Insert Truck Exhaust Cone Tool (special tool #8404-ECT, Exhaust Cone, Truck), into the vehicle tail pipe.
- If the vehicle is equipped with dual exhaust, use the Truck Exhaust Cone Tool (special tool #8404-ECT, Exhaust Cone, Truck), equipped with attached plug. Plug one side of the dual exhaust pipe. Pressurize the other as described.
- Apply a mixture of MOPAR® Air Leak Detector to the following areas:
- All welded joints from 6 inches rearward of the downstream Oxygen (O2) sensor forward
- O2 sensor seal points
- O2 sensor boss welds
- Flange/Joint connection(s)
- Exhaust manifold to cylinder head connection(s)
- Exhaust Gas Resonator (EGR) cooler to exhaust manifold connection(s)
- EGR bypass valve connection(s)
- EGR crossover tube connection(s)
- EGR solenoid gasket base and tube seal points (if equipped)
- Watch for the Air Detector to bubble.
- 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 (.039 in.) 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 8 mm (0.32 in.) or greater appear. A Type 2 Leak may also include at hissing sound (air pressure escaping) if the opening is to large to create bubbles. 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.
| Leak Location | Repair required if results at 4 psi reveal bubble size or hissing sound: |
|---|---|
| Welded joints | Type 1 - 1 mm (.039 in.) or greater |
| O2 Sensor seal points | Type 1 - 1 mm (.039 in.) or greater |
| O2 Sensor boss welds | Type 1 - 1 mm (.039 in.) or greater |
| Flange/joint connections | Type 2 - 8 mm (.32 in.) or greater |
| Exhaust Manifold to cylinder head connections | Type 2 - 8 mm (.32 in.) or greater |
| EGR gasket | Type 2 - 8 mm (.32 in.) or greater |
| EGR cooler to exhaust manifold connections | Type 2 - 8 mm (.32 in.) or greater |
| EGR bypass valve connections | Type 2 - 8 mm (.32 in.) or greater |
| EGR crossover tube connections | Type 2 - 8 mm (.32 in.) or greater |
If a leak is found that matches the above definition, repair or replace the component as necessary.
Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.