Dodge Dakota (R1). Manual - part 547

CAUTION: Avoid application of rust prevention com-
pounds or undercoating materials to exhaust sys-
tem 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.

The gasoline engine exhaust system consists of

engine exhaust manifolds, exhaust pipes, catalytic
converter(s), extension pipe (if needed), exhaust heat
shields, muffler and exhaust tailpipe.

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 con-
tacts any body panel, it may amplify objectionable
noises from the engine or body (Fig. 1).

DESCRIPTION—EXHAUST SYSTEM 3.9L/4.7L
AND 5.9L ENGINES

EXHAUST SYSTEM

11 - 1

The gasoline engine exhaust system consists of

engine exhaust manifolds, exhaust pipes, catalytic
converter(s), extension pipe (if needed), exhaust heat
shields, muffler and exhaust tailpipe.

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 con-
tacts any body panel, it may amplify objectionable
noises from the engine or body (Fig 2).

Fig. 1 Exhaust System 2.5L Engines—Typical

1 - TAILPIPE
2 - MUFFLER
3 - MUFFLER HANGER BRACKET AND ISOLATOR
4 - CLAMP

5 - EXHAUST PIPE
6 - CATALYTIC CONVERTER
7 - EXTENSION PIPE
8 - MUFFLER HEAT SHIELD

Fig. 2 Exhaust System 3.9L, 4.7L and 5.9L Engines—Typical

1 - TAILPIPE
2 - MUFFLER HANGER BRACKET AND ISOLATOR
3 - CLAMP
4 - EXHAUST PIPE

5 - CATALYTIC CONVERTER
6 - EXTENSION PIPE
7 - MUFFLER HEAT SHIELD

11 - 2

EXHAUST SYSTEM

EXHAUST SYSTEM (Continued)

DIAGNOSIS AND TESTING—EXHAUST SYSTEM

EXHAUST SYSTEM DIAGNOSIS CHART

CONDITION

POSSIBLE CAUSE

CORRECTION

EXCESSIVE EXHAUST NOISE

1. Leaks at pipe joints.

1. Tighten clamps to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).

2. Burned or blown out muffler.

2. Replace muffler assembly (Refer
to 11 - EXHAUST SYSTEM/
MUFFLER - REMOVAL). Check
exhaust system.

3. Burned or rusted-out exhaust
pipe.

3. Replace exhaust pipe (Refer to
11 - EXHAUST SYSTEM/EXHAUST
PIPE - REMOVAL).

4. Exhaust pipe leaking at manifold
flange.

4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).

5. Exhaust manifold cracked or
broken.

5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).

6. Leak between exhaust manifold
and cylinder head.

6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).

7. Restriction in muffler or tailpipe.

7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.

8. Exhaust system contacting body
or chassis.

8. Re-align exhaust system to clear
surrounding components.

LEAKING EXHAUST GASES

1. Leaks at pipe joints.

1. Tighten/replace clamps at leaking
joints (Refer to 11 - EXHAUST
SYSTEM - SPECIFICATIONS).

EXHAUST SYSTEM

11 - 3

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