Engine Exhaust

2008 Chrysler Aspen Limited
2008 ENGINE Exhaust System - Aspen & Durango
2008 ENGINE
Exhaust System - Aspen & Durango
DESCRIPTION
EXHAUST SYSTEM-DESCRIPTION
Fig. 1: Exhaust System 4.7L/5.9L - Typical

Courtesy of CHRYSLER LLC
1 - BALL FLANGE
2 - CATALYTIC CONVERTER
3 - CLAMP
4 - EXHAUST PIPE
5 - INSULATOR
6 - MUFFLER
7 - TAILPIPE AND RESONATOR ASSEMBLY
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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11:37:56 AM Page 1 © 2006 Mitchell Repair Information Company, LLC.
Fig. 2: Exhaust System - 5.7L

1 - BALL FLANGE
2 - RH CATALYTIC CONVERTER
3 - CLAMP
4 - ISOLATOR
5 - MUFFLER
6 - TAILPIPE AND RESONATOR ASSEMBLY
7 - LH CATALYTIC CONVERTER ASSEMBLY
The gasoline engine exhaust system consists of engine exhaust manifolds, exhaust pipes (4) , catalytic converter
(s) (2), extension pipe (if needed) (4), exhaust heat shields , muffler (6) and tailpipe and resonator assembly (7).
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
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Tuesday, April 27, 2010 11:37:56 AM Page 2 © 2006 Mitchell Repair Information Company, LLC.
panel, it may amplify objectionable noises from the engine or body.
OPERATION
OPERATION
The exhaust system channels exhaust gases from the engine and away from the vehicle.
DIAGNOSIS AND TESTING

EXHAUST SYSTEM
CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps to specified
torque at leaking joints. See
SPECIFICATIONS.
2. Burned or blown out muffler. 2. Replace muffler assembly. See
REMOVAL. Check exhaust
system.
3. Burned or rusted-out exhaust 3. Replace exhaust pipe.
pipe.
4. Exhaust pipe leaking at 4. Tighten connection attaching
manifold flange. nuts. See SPECIFICATIONS.
5. Exhaust manifold cracked or 5. Replace exhaust manifold. Refer
broken. to REMOVAL - 3.7L. Refer to
REMOVAL - 4.7L. Refer to
REMOVAL - 5.7L.
6. Leak between exhaust 6. Tighten exhaust manifold to
manifold and cylinder head. cylinder head stud nuts or bolts.
Refer to SPECIFICATIONS -
3.7L. Refer to SPECIFICATIONS
- 4.7L. Refer to
SPECIFICATIONS - 5.7L.
7. Restriction in muffler or 7. Remove restriction, if possible.
tailpipe. Replace muffler or tailpipe, as
necessary.
8. Exhaust system contacting 8. Re-align exhaust system to clear
body or chassis. surrounding components.
LEAKING EXHAUST GASES 1. Leaks at pipe joints. 1. Tighten/replace clamps at leaking
joints. See SPECIFICATIONS.
SPECIFICATIONS
TORQUE
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DESCRIPTION N.m Ft. Lbs. In. Lbs.

Exhaust Clamp Nuts (All) 61 45 -
Exhaust Pipe to Manifold Nuts 34 25 -
Heat Shield Nuts 7 - 60
Muffler Hanger Bolts 23 - 200
Tailpipe Hanger Bolt 23 - 200
CONVERTER-CATALYTIC
DESCRIPTION
DESCRIPTION
All vehicles incorporate toe board catalytic converters into the exhaust system. These catalytic converters are
made of stainless steel designed to operate at extremely high temperatures.
OPERATION
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
REMOVA-5.7L ENGINE
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Fig. 3: Removing 5.7L Catalytic Converter

1 - CATALYTIC CONVERTER-to-MANIFOLD BOLTS

3 - LH-TO-LH CATALYTIC CONVERTER CLAMP
4 - LH CATALYTIC CONVERTER
CAUTION: When servicing or 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. Raise and support the vehicle.

2. Saturate all exhaust bolts and nuts with Mopar® Rust Penetrant. Allow 5 minutes for penetration.
3. Remove the clamp (3) holding the LH catalytic converter (4) to the RH catalytic converter (2).
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4. If present, grind any tack welds.

5. Remove the catalytic converter-to-manifold bolts (1).
6. Remove the LH catalytic converter (4) from the RH catalytic converter (2).
7. Remove the clamp holding the RH catalytic converter (2) to the exhaust pipe(s).
8. If present, grind tack weld.
9. Remove the RH catalytic converter (2) from the extension pipe.
10. You may have to loosen up other sections of the exhaust system.
REMOVAL-3.7L/4.7L ENGINE
Fig. 4: Catalytic Converter - 3.7L/4.7L

1 - CLAMP
2 - EXHAUST PIPE
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4 - BOLT


2. Saturate all exhaust bolts and nuts with Mopar® Rust Penetrant. Allow 5 minutes for penetration.
3. Disconnect the oxygen senor electrical connectors.
4. Remove the catalytic converter-to-manifold bolts (5).
5. Remove the clamp (1) holding the catalytic converter (3) to the exhaust pipe(s) (2).
6. If present, grind tack weld.
7. Remove the clamp holding the catalytic converter flange to the muffler or extension pipe.
8. Remove the catalytic converter. You may have to loosen up other sections of the exhaust system.
INSPECTION
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
INSTALLATION-3.7L/4.7L ENGINE
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Fig. 5: Catalytic Converter - 3.7L/4.7L

1 - CLAMP
2 - EXHAUST PIPE
4 - BOLT

NOTE: The band clamps are not reusable. After removal, they must be replaced with
new one.
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1. Make sure the catalytic converter assembly (3) is free of burrs.

2. Insert the catalytic converter assembly (3) into the exhaust pipe (2).
3. Make sure the alignment tang is fully seated in the alignment slot.
4. Position catalytic converter assembly (3) to exhaust manifold and install flange nuts (5) and bolts (4). Do
not tighten at this time.
5. If other sections of the exhaust system where loosened in removal, refer to Specifications for the
tightening procedures.
6. At the catalytic converter-to-extension pipe connection, install new clamp (1) and nuts. Do not tighten at
this time.
7. Make sure the catalytic converter assembly (3) is correctly positioned and the properly aligned. The
minimum clearance between components is 25mm (1 inch). Ensure that muffler isolators are not
stretched. Measurement between insulator rods is approximately 42mm (1.65 in.). Make the necessary
adjustments, if necessary.
8. Tighten exhaust manifold flange bolts to 33 N.m (25 ft. lbs.)
9. Tighten the clamp nuts to 61 N.m (45 ft. lbs.) torque.
10. Lower the vehicle.
11. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary.
INSTALLATION-5.7L ENGINE
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Fig. 6: Installing 5.7L Catalytic Converter

1 - CATALYTIC CONVERTER-to-MANIFOLD BOLTS

3 - LH-TO-LH CATALYTIC CONVERTER CLAMP
4 - LH CATALYTIC CONVERTER
NOTE: The band clamps are not reusable. After removal, the must be replaced.

2. Remove any burrs from the RH (2) and LH (4) catalytic converter.
3. Position new RH catalytic converter-to-exhaust pipe clamp on exhaust pipe. Insert the RH (2) catalytic
converter into the exhaust pipe. Do not tighten clamp at this time.
4. Make sure the alignment tang is seated in the alignment slot.
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5. Position new RH catalytic converter-to-LH catalytic converter clamp on RH catalytic converter. Insert the
LH catalytic converter (4) into the RH catalytic converter (2). Do not tighten clamp at this time.
6. Make sure the alignment tang is seated in the alignment slot.
7. Install the LH and RH catalytic converters (2 and 4) to the exhaust manifold. Install bolts. Do not tighten
at this time.
8. Connect the oxygen sensor electrical connectors.
9. Make sure the catalytic converter assembly (2 and 4) are correctly positioned and the properly aligned.
The minimum clearance between components is 25mm (1 inch). Ensure that the exhaust crossover has at
least 15mm (.59 in.) clearance at transmission crossmember. Ensure that muffler isolators are not
stretched. Measurement between insulator rods is approximately 42mm (1.65 in.). Make the necessary
adjustments, if necessary.
10. Tighten manifold flange bolts to 34 N.m (24 lbs. ft.). Tighten the new exhaust clamps to 61 N.m (45 lbs.
ft).
11. If other sections of the exhaust system where loosened in removal, refer to Specifications for the
tightening procedures.
SHIELDS-HEAT
DESCRIPTION
DESCRIPTION
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Fig. 7: Muffler Heat Shield

1 - MUFFLER HEAT SHIELD

2 - MUFFLER HANGERS
There are two types of heat shields (1) used. One is stamped steel the other is molded foil sheets. The shields
attach to the vehicle around the exhaust system.
OPERATION
OPERATION
The heat shields prevent heat from the exhaust system from entering the passenger area and other areas where
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the heat can cause damage to other components.
REMOVAL
REMOVAL


2 - MUFFLER HANGERS

2. Disconnect oxygen sensor electrical connectors.
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3. Remove the screws and nuts holding the heat shields (1) to the frame and floor pan.
4. Slide the heat shield (1) out around the exhaust system.
INSTALLATION
INSTALLATION


2 - MUFFLER HANGERS
1. Position the heat shields to the floor pan or the frame and install the screws and nuts.
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2. Tighten the screws/nuts to 7 N.m (60 in. lbs.) torque.

3. Connect oxygen sensor electrical connectors.
MUFFLER
DESCRIPTION
DESCRIPTION
Fig. 10: View Of Muffler & Components

1 - CATALYTIC CONVERTER WITH PIPE

2 - REAR MUFFLER HANGER
3 - MUFFLER
4 - CLAMP
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All engines use a stainless steel muffler (5) to control exhaust noise levels and exhaust back pressure.
OPERATION
OPERATION
The muffler is designed to muffle the sound of the exhaust as it leaves the engine.
REMOVAL
REMOVAL


3 - MUFFLER
4 - CLAMP
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1. Raise vehicle on hoist.

2. Remove the tail pipe. See REMOVAL.
3. Remove the muffler-to-catalytic converter clamp (3).
4. Remove the muffler isolators (1 and 4).
5. Remove the muffler (5) from the catalytic converter.
INSTALLATION
INSTALLATION


3 - MUFFLER
4 - CLAMP
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NOTE: The band clamps are not reusable. After removal, they must be replaced.
1. Install muffler to the catalytic converter or exhaust pipe.

2. Make sure the alignment tang seats in the alignment slot.
3. Install new exhaust clamps. Do not tighten at this time.
4. Install muffler isolators. Ensure muffler isolators are not stretched. The measurement between hangers
should be 42mm (1.65 in.).
5. Align muffler and exhaust pipe. Tighten exhaust clamp nuts to 61 N.m (45 ft. lbs.).
6. Check the exhaust system for contact with body panels. Make the necessary adjustments, if necessary.
7. Lower vehicle.
8. Start engine and check for exhaust leaks. Repair exhaust leaks as necessary.
TAILPIPE
DESCRIPTION
DESCRIPTION
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Fig. 13: Locating Exhaust Pipe to Manifold Connection - 3.9L/5.9L

1 - EXHAUST PIPE INSULATOR

2 - EXHAUST PIPE
3 - EXHAUST PIPE-TO-MUFFLER CLAMP
4 - MUFFLER
5 - MUFFLER INSULATOR
The tailpipe is made of stainless steel and attaches to the muffler.
OPERATION
OPERATION
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The tailpipe channels the exhaust out of the muffler and out from under the vehicle to control noise and prevent
exhaust gas fumes from entering the passenger compartment.
REMOVAL
REMOVAL
Fig. 14: Removing Exhaust Pipe to Manifold Connection - 3.9L/5.9L


2 - EXHAUST PIPE
4 - MUFFLER
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WARNING: If torches are used when working on the exhaust system, wear protective
eye covering and do not allow the flame near the fuel lines.
CAUTION: When servicing or replacing exhaust system components, be sure to

disconnect all oxygen sensor connectors. Allowing the exhaust system to
hang by the harness will damage the wiring and/or sensor.

2. Saturate the bolts and nuts with Mopar® Rust Penetrant. Allow 5 minutes for penetration.
3. Remove the exhaust pipe-to-muffler clamp (3).
4. Grind any tack weld, if present.
5. Remove the exhaust pipe insulators (1).
6. Remove the rear muffler insulators (5) if necessary.
7. If necessary, heat connection with an oxygen/acetylene torch and twist tailpipe out of muffler.
8. Remove the exhaust pipe (2) from the muffler (4).
INSPECTION
INSPECTION
Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original
equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide
acceptable exhaust noise levels.
INSTALLATION
INSTALLATION
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Fig. 15: Installing Exhaust Pipe to Manifold Connection - 3.9L/5.9L


2 - EXHAUST PIPE
4 - MUFFLER
NOTE: The band clamps are not reusable. After removal, they must be replaced.
1. Remove any burrs from the exhaust pipe (2).

2. Connect the exhaust pipe (2) to the muffler (4).
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3. Make sure that the alignment tang is seated in the alignment slot.
4. Install the muffler-to-exhaust pipe clamp. Do not tighten at this time.
5. Install the rear muffler insulators (5), if removed.
6. Install the tail pipe insulators (1)
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if necessary.
8. Tighten muffler-to-exhaust pipe clamp to 61 N.m (45 ft. lbs.).
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2008 Chrysler Aspen Limited

2008 ENGINE Exhaust System - Aspen & Durango

Exhaust System - Aspen & Durango

Fig. 1: Exhaust System 4.7L/5.9L - Typical

CAUTION: Avoid application of rust prevention compounds or undercoating materials

Fig. 2: Exhaust System - 5.7L

panel, it may amplify objectionable noises from the engine or body.

DIAGNOSIS AND TESTING

CONDITION POSSIBLE CAUSE CORRECTION

DESCRIPTION N.m Ft. Lbs. In. Lbs.

Fig. 3: Removing 5.7L Catalytic Converter

1 - CATALYTIC CONVERTER-to-MANIFOLD BOLTS

CAUTION: When servicing or replacing exhaust system components, disconnect the

1. Raise and support the vehicle.

4. If present, grind any tack welds.

Fig. 4: Catalytic Converter - 3.7L/4.7L

CAUTION: When servicing or replacing exhaust system components, disconnect the

1. Raise and support the vehicle.

Fig. 5: Catalytic Converter - 3.7L/4.7L

CAUTION: When servicing or replacing exhaust system components, disconnect the

1. Make sure the catalytic converter assembly (3) is free of burrs.

Fig. 6: Installing 5.7L Catalytic Converter

1 - CATALYTIC CONVERTER-to-MANIFOLD BOLTS

1. Raise and support the vehicle.

Fig. 7: Muffler Heat Shield

1 - MUFFLER HEAT SHIELD

the heat can cause damage to other components.

Fig. 8: Muffler Heat Shield

1 - MUFFLER HEAT SHIELD

1. Raise and support the vehicle.

Fig. 9: Muffler Heat Shield

1 - MUFFLER HEAT SHIELD

2. Tighten the screws/nuts to 7 N.m (60 in. lbs.) torque.

Fig. 10: View Of Muffler & Components

1 - CATALYTIC CONVERTER WITH PIPE

Fig. 11: View Of Muffler & Components

1 - CATALYTIC CONVERTER WITH PIPE

1. Raise vehicle on hoist.

Fig. 12: View Of Muffler & Components

1 - CATALYTIC CONVERTER WITH PIPE

1. Install muffler to the catalytic converter or exhaust pipe.

Fig. 13: Locating Exhaust Pipe to Manifold Connection - 3.9L/5.9L

1 - EXHAUST PIPE INSULATOR

The tailpipe is made of stainless steel and attaches to the muffler.

Fig. 14: Removing Exhaust Pipe to Manifold Connection - 3.9L/5.9L

1 - EXHAUST PIPE INSULATOR

CAUTION: When servicing or replacing exhaust system components, be sure to

1. Raise and support the vehicle.

Fig. 15: Installing Exhaust Pipe to Manifold Connection - 3.9L/5.9L

1 - EXHAUST PIPE INSULATOR

1. Remove any burrs from the exhaust pipe (2).

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