The Basic Exhaust System
Most vehicles have a single exhaust system which includes a catalytic converter, a long length of pipe and a
muffler. this long length of pipe can be fitted over a section of pipe extending
from the converter and fitted into a section of pipe welded to the muffler.
In some applications, these connections might be flange connections, making removal much easier. On V-engines, there will be a crossover
pipe, formed from exhaust pipes from each exhaust manifold that are welded together to make a single pipe.
There are probably several metal hangers, welded to the pipe, that are inserted into rubber isolators to
support the exhaust system. Finally, don't forget that the downstream oxygen sensor is installed in the
catalytic converter. Save this sensor and install it in the new converter.
Inspection and Removal
Let's begin at the tailpipe and muffler. Inspect all the seams of the muffler,
including the weld of the pipe on the inlet side for holes and leaks. Note that on Chrysler O.E. mufflers there is
a small vent hole, A, on the outlet side of the muffler (see Figure 1).
This allows water vapour to escape from the muffler; thus, preventing rust and extending the service life. Be sure that the
replacement muffler has a vent hole.
As we move along the exhaust pipe toward the engine, the surface of the pipe will be rust covered. Inspect the
pipe and catalytic converter for cracked joints, broken welds and corrosion damage that would result in a leaking
exhaust system. You'll see that pipe clamps will be severely rusted on a vehicle with a lot of kilometres, B. Spray
the clamp with Mopar Rust Penetrant, P/N 04318039AB, to aid in removal of the clamp, C (see Figure 2).
Begin the removal of the exhaust system at the exhaust manifold. Depending on the design, there might three or four bolts at the flanged
connections, D. Be sure to install a new manifold gasket, E (see Figure 3).
If the entire exhaust system is being removed, drop the exhaust pipe and converter at the engine
and then remove hangers from the rubber isolators. If a section of pipe is being removed, loosen the clamp bolt, F, in order to
separate the two pipes (see Figure 4).
Now, it might be very difficult to separate the pipe. You might have to resort to sawing the pipe. If you have a
cutting torch (not many people have one in their garage), you can cut the pipe. In both of these scenarios, an
adapter will be necessary to install the new piece.
Installation
When installing a new exhaust, do not tighten the clamp bolts until all the pieces are correctly aligned and clearances are checked and verified.
Begin at the exhaust manifold (refer to Figure 3) and install the short pipe and converter, or crossover pipe (don't forget to install the downstream
oxygen sensor in the converter).
Next, fit the long pipe, G, over the short pipe, H, from the converter as shown in Figure 5 (Note: there might
be a tab, J, on the pipe that fits into a vee on the long pipe to ensure proper alignment). Then, install the muffler
by fitting the inlet pipe onto the long pipe (the same tab and vee will be on these two pieces). Finally, insert the
hangers, K, into the rubber isolators, L (see Figure 6).
To finish the job, properly align the entire exhaust system, being sure that the proper clearances exist between
the floor pan, M, and heat shields, N, of the vehicle (see Figure 7). Also, be sure that the tailpipe, O, is properly
aligned with the rear fascia opening, P, as can be seen in Figure 8. Nothing says “lousy job†like the tailpipe touching
the bumper cover.
When all is in place, tighten the clamps and the job is done.
Courtesy of Mopar Magazine |
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
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