PM EXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM

TABLE OF CONTENTS
page page

EXHAUST SYSTEM AND TURBOCHARGER CONVERTER CATALYTIC

DESCRIPTION
GAS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK . . . . . . . . . . . . . 3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS
EXHAUST SYSTEM ADJUSTMENTS . . . . . . . . . . . 4
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MUFFLER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION - GAS ENGINE . . . . . . . . . . . . . . . . . . . . 8
REMOVAL
UNDER FLOOR CATALYTIC CONVERTER . . . . . 9
CATALYTIC CONVERTER - FWD . . . . . . . . . . . . . 10
REMOVAL - MANIVERTER . . . . . . . . . . . . . . . . . . . 10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION
UNDER FLOOR CATALYTIC CONVERTER . . . . 11
CATALYTIC CONVERTER - FWD . . . . . . . . . . . . . 12
INSTALLATION - MANIVERTER . . . . . . . . . . . . . . 12
SHIELDS HEAT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
11 - 2 EXHAUST SYSTEM PM

EXHAUST SYSTEM AND TURBOCHARGER

DESCRIPTION
GAS ENGINE

The FWD gas engine exhaust system components consist of a catalytic converter, intermediate pipe, muffler,
clamps and support isolators

The AWD gas engine exhaust system components consist of a maniverter, under floorcatalytic converter, interme-
diate pipe, muffler, clamps and support isolators
PM EXHAUST SYSTEM 11 - 3

DIAGNOSIS AND TESTING

EXHAUST SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

EXCESSIVE EXHAUST 1. Exhaust manifold cracked or 1. Replace manifold.

NOISE (UNDER HOOD) broken.

2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace gasket.

3. Exhaust flex joint to manifold leak. 3.Tighten fasteners or replace gasket.
4. Exhaust flex joint. 4. Replace catalytic converter assembly.
5. Pipe and shell noise from front 5. Characteristic of single wall pipes.
exhaust pipe.

EXCESSIVE EXHAUST 1. Leaks at pipe joints. 1. Tighten or replace clamps at leaking

NOISE
2. Burned, blown, or rusted out
exhaust pipe or muffler.
3. Restriction in muffler or tailpipe.
4. Catalytic converter material in
muffler.
joints.
2. Replace muffler or exhaust pipes.
3. Remove restriction, if possible or replace
as necessary.
4. Replace muffler and converter assembly.
Check fuel injection and ignition systems for
proper operation.

DIAGNOSIS AND TESTING - EXHAUST SYSTEM RESTRICTION CHECK

Exhaust system restriction can be checked by measuring back pressure using the DRB IIIT and PEP module pres-
sure tester.

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.

NOTE: For Special Tool identification, (Refer to 11 - EXHAUST SYSTEM - SPECIAL TOOLS).

1. Disconnect and remove the upstream (before catalytic converter) oxygen sensor. (Refer to 14 - FUEL SYSTEM/
FUEL INJECTION/O2 SENSOR - REMOVAL)
2. Install the Back Pressure Test Adaptor CH8519.
3. Connect the Pressure Transducer CH7063 to the back pressure fitting.
4. Following the PEP module instruction manual, connect all required cables to the DRB IIIT and PEP module.
Select the available menu options on the DRBIIIT display screen for using the digital pressure gauge function.
5. Apply the park brake and start the engine.
6. With transmission in Park or Neutral, raise engine speed to 2000 RPM. Monitor the pressure readings on the
DRBIIIT. Back pressure should not exceed specified limit. Refer to specification in table below EXHAUST BACK
PRESSURE LIMITS .
7. If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic con-
verter inspection procedures, (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSPECTION).
Replace component(s) as necessary.
11 - 4 EXHAUST SYSTEM PM

EXHAUST BACK PRESSURE LIMITS

Exhaust Back Pressure Limit (Max)

Vehicle in Park/Neutral (no load) @2000 RPM 3.45 Kpa (0.5 psi)

INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and corro-
sion damage that would result in a leaking exhaust system. Inspect the clamps, support brackets, and insulators for
cracks and corrosion damage.

NOTE: Slip joint band clamps are spot welded to exhaust system. If a band clamp must be replaced, the
spot weld must be ground off.

ADJUSTMENTS
EXHAUST SYSTEM ADJUSTMENTS
A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system com-
ponents. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system for
broken or loose clamps, heat shields, insulators, and brackets. Replace or tighten as necessary. It is important that
exhaust system clearances and alignment be maintained.
Perform the following procedures to align the exhaust system:
1. Loosen clamps and support brackets.
2. Align the exhaust system starting at the front, working rearward.
3. Tighten all clamps and brackets once alignment and clearances are achieved.

SPECIFICATIONS
TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
Fastener, Band Clamps 55 40 -
Fasteners, Catalytic Converter to Exhaust Manifold Flange 28 - 250
Fastener, under floor catalytic converter to maniverter - AWD 33 24 -
Fasteners, Intermediate Pipe Heat Shield 3.7 - 33
Fasteners, Support Brackets (Frame Rail Mounted) 8.5 - 75
Fasteners, Support Bracket (Rear Panel Mounted) 3.7 - 33
Fasteners, Charge Air Cooler 8 - 70
Hose Clamps, Charge Air Cooler 1.7 - 15
Banjo Fitting, Coolant Line 37 27 -
Brass Fitting, Coolant/Oil Line 41 30 -
Flared Fitting, Coolant/Oil Line 31 23 -
Elbow 28 - 250
Elbow Support Bracket
M8 Fasteners 28 - 250
M10 Fasteners 54 40 -
Fasteners, Exhaust Manifold/Turbocharger Assembly to Cylinder
28 - 250
Head
Fasteners, Heat Shield 28 - 250
Fasteners, Oil Return Tube 12 - 105
Turbocharger Support Bracket 54 40 -
PM EXHAUST SYSTEM 11 - 5

SPECIAL TOOLS
EXHAUST SYSTEM

DRB III & PEP Module - OT-CH6010A

Back Pressure Test Adapter - CH8519

Pressure Transducer CH7063

11 - 6 EXHAUST SYSTEM PM

MUFFLER
REMOVAL
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 oper-
ating time.

NOTE: When replacement is required on any com-

ponent of the exhaust system, you must use orig-
inal equipment parts (or their equivalent).

1. Raise vehicle on hoist and apply penetrating oil to

band clamp nut and bolt of component being
removed.

NOTE: Do not use petroleum-based lubricants

when removing/installing muffler or exhaust pipe isolators (3) as it may compromise the life of the part. A
suitable substitute is a mixture of liquid dish soap and water.

2. Remove exhaust system ground strap (1) at rear of I-Pipe/Muffler assembly (2).
3. Loosen band clamp and remove support isolators (3) at I-Pipe/Muffler assembly (2). Remove I-Pipe/Muffler
assembly (2) from catalytic converter.
4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators, rusted or over-
used clamps, supports, and attaching parts.

INSTALLATION
When assembling exhaust system do not tighten
clamp until components are aligned and clearances
are checked.
1. Install the I-Pipe/Muffler assembly to catalytic con-
verter and the isolator supports to the underbody.
PM EXHAUST SYSTEM 11 - 7

2. Working from the front of system; align each com-

ponent to maintain position and proper clearance
with underbody parts. For clearance specifications
(Refer to 11 - EXHAUST SYSTEM - SPECIFICA-
TIONS). Tighten band clamp to 55 N·m (40 ft. lbs.).

CAUTION: Band clamps should never be tightened

such that the two sides of the clamps are bot-
tomed out against the center hourglass shaped
center block. Once this occurs, the clamp band
has been stretched and has lost its clamping force
and must be replaced.
To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. File
or grind remaining weld material until pipe surface is smooth.

NOTE: Maintain proper clamp orientation when replacing with new clamp.

3. Connect the exhaust system ground strap.

4. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
5. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
11 - 8 EXHAUST SYSTEM PM

CONVERTER CATALYTIC
DESCRIPTION
The combination exhaust manifold/catalytic converter is attached to the intermediate pipe using fasteners and a
gasket for sealing.

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 con-
verter, 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.
FWD vehicles use a catalytic converter located after the exhaust manifold and before the I-Pipe/Muffler assembly.
AWD vehicles use a maniverter and a underfloor catalytic converter. The underfloor catalytic converter is located
between the maniverter and the I-Pipe/muffler assembly.
Diesel engine vehicles use a catalytic converter located between the turbocharger and the I-Pipe/Muffler assembly.

OPERATION - GAS ENGINE

The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases. Specifi-
cally, HC and CO emissions are converted into water (H2O) and carbon dioxide (CO2). Oxides of Nitrogen (NOx)
are converted into Nitrogen (N) and Oxygen. The three-way catalyst is most efficient in converting HC, CO and NOx
at the stoichiometric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a high oxygen content
(lean) air/fuel ratio is present for an extended period, oxygen content in a catalyst can reach a maximum. When a
rich air/fuel ratio is present for an extended period, the oxygen content in the catalyst can become totally depleted.
When this occurs, the catalyst fails to convert the gases. This is known as catalyst 9punch through.9
Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-
reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst’s
ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of
catalyst performance. Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Diagnostic
Trouble Code (DTC).
The combustion reaction caused by the catalyst releases additional heat in the exhaust system, causing tempera-
ture increases in the area of the reactor under severe operating conditions. Such conditions can exist when the
engine misfires or otherwise does not operate at peak efficiency. 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 temperature increases
caused by unburned fuel passing through the converter. This deterioration of the catalyst core can result in exces-
sively high emission levels, noise complaints, and exhaust restrictions.
Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate above 1200
RPM in neutral for extended periods over 5 minutes. This condition may result in excessive exhaust system/floor
pan temperatures because of no air movement under the vehicle.
The flex joint allows flexing as the engine moves, preventing breakage that could occur from the back-and-forth
motion of a transverse mounted engine.
PM EXHAUST SYSTEM 11 - 9

CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme
care should be taken with replacement parts. There are internal converter differences required in some
parts of the country (particularly vehicles built for States with strict emission requirements) and between
model years.

REMOVAL
UNDER FLOOR CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE 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 TEM-
PERATURE OF THE CONVERTER RISES TO A
HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATING TIME.

1. Raise vehicle on hoist and apply penetrating oil to

band clamp fastener of component being removed.

NOTE: Do not use petroleum-based lubricants

when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part.
A suitable substitute is a mixture of liquid dish
soap and water.

2. Remove I-Pipe/Muffler assembly (Refer to 11 - EXHAUST SYSTEM/MUFFLER - REMOVAL).

3. Disconnect oxygen sensor electrical connectors.

NOTE: If spherical gasket is to be reused, mark orientation.

4. Remove flange bolts (3), springs and spherical gasket.

5. Remove under floor catalytic converter (3) from combination manifold/catalytic converter assembly (1).
6. Clean ends of pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps,
supports, and attaching parts.

NOTE: When replacement is required on any component of the exhaust system, you must use original
equipment parts (or their equivalent).
11 - 10 EXHAUST SYSTEM PM

CATALYTIC CONVERTER - FWD

WARNING: The normal operating temperature of
the exhaust system is very high. Therefore, never
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.

NOTE: Before replacing a catalytic converter,

determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or igni-
tion problems. Refer to the appropriate service
diagnostic information for repair procedures.

1. Loosen intermediate pipe-to catalytic converter

clamp.

NOTE: Do not use petroleum-based lubricants

when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and
water.

2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle.
3. Remove I-Pipe/Muffler assembly insolators as necessary to slide I-Pipe/Muffler assembly out of catalytic con-
verter.
4. Remove and discard flange gasket.

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or
equivalent) must be used.

REMOVAL - MANIVERTER
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A
SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: Before replacing a catalytic converter,

determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or igni-
tion problems. Refer to the appropriate service
diagnostic information for repair procedures.

1. Remove under floor catalytic converter (Refer to 11

- EXHAUST SYSTEM/CATALYTIC CONVERTER -
REMOVAL).

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or
equivalent) must be used.
PM EXHAUST SYSTEM 11 - 11

2. Lower vehicle.
3. Remove secondary thermostat (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT -
REMOVAL).
4. Remove maniverter mounting bolts.
5. Remove maniverter and gasket from the engine compartment.

INSPECTION
WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never 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.

Check catalytic converter for a flow restriction. (Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS AND TESTING)
Exhaust System Restriction Check for procedure.
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen sensor(s) and
insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect
element for cracked or melted substrate.

NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter
failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test
procedures.

INSTALLATION
UNDER FLOOR CATALYTIC CONVERTER
When assembling exhaust system do not tighten
clamps until components are aligned and clearances
are checked.
1. Install under floor catalytic converter and the isola-
tor supports to the underbody.
2. Position spherical gasket (2) with white side facing
rear of vehicle, install springs, and bolts (3).
Tighten bolts to 33 N·m (24 ft. lbs.).
3. Install I-Pipe/muffler assembly (Refer to 11 -
EXHAUST SYSTEM/MUFFLER - INSTALLATION)
4. Working from the front of system; align each com-
ponent to maintain position and proper clearance
with underbody parts.

5. Tighten band clamps to 55 N·m (40 ft. lbs.).

CAUTION: Band clamps should never be tightened

such that the two sides of the clamps are bot-
tomed out against the center hourglass shaped
center block. Once this occurs, the clamp band
has been stretched and has lost its clamping force
and must be replaced.

NOTE: Maintain proper clamp orientation when

replacing with new clamp.
11 - 12 EXHAUST SYSTEM PM

6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

CATALYTIC CONVERTER - FWD

1. Position catalytic converter into I-Pipe/muffler
assembly.
2. Using new gasket position catalytic converter
against exhaust manifold.
3. Install flange bolts. Tighten to 29 N·m (21 ft. lbs.).
4. Working from the front of system; align each com-
ponent to maintain position and proper clearance
with underbody parts.
5. Tighten band clamps to 55 N·m (40 ft. lbs.).

CAUTION: Band clamps should never be tightened

such that the two sides of the clamps are bot-
tomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
clamping force and must be replaced.

6. Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if needed.

INSTALLATION - MANIVERTER
NOTE: When assembling exhaust system do not
tighten clamps until all components are aligned
and clearances are checked.

1. Position maniverter (1) in vehicle. Use a new

flange gasket.
2. Using new gasket, install maniverter (1) and
mounting bolts. Tighten bolts to 28 N·m (250 in.
lbs.).
3. Install secondary thermostat (Refer to 7 - COOL-
ING/ENGINE/ENGINE COOLANT THERMOSTAT -
INSTALLATION).
4. Install under floor catalytic converter (Refer to 11 -
EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSTALLATION).
5. Working from the front of system; align each com-
ponent to maintain position and proper clearance
with underbody parts.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
PM EXHAUST SYSTEM 11 - 13

SHIELDS HEAT
DESCRIPTION
Heat shields (1), are needed to protect both the vehi-
cle and the environment from the high temperatures
developed in the vicinity of the catalytic converter.

CAUTION: Avoid application of rust prevention

compounds or undercoating materials to exhaust
system floor pan heat shield on cars if equipped.
Light over-spray near the edges is permitted.
Application of coating will greatly reduce the effi-
ciency of the heat shields resulting in excessive
floor pan temperatures and objectionable fumes.

REMOVAL
1. Raise vehicle on hoist.
2. Remove fasteners attaching heat shield.
3. Remove heat shield (s)

INSTALLATION
1. Position heat shield(s) to underbody.
2. Install heat shield fasteners.
3. Inspect heat shield to exhaust system clearances
and adjust as necessary. For clearance specifica-
tions (Refer to 11 - EXHAUST SYSTEM - SPECI-
FICATIONS).
4. Lower vehicle.
5. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
6. Check the exhaust system for contact with the
body panels. Make the necessary adjustments, if
needed.