WK EXHAUST SYSTEM 11 - 1

EXHAUST SYSTEM

TABLE OF CONTENTS
page page

EXHAUST SYSTEM 4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION 5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GAS ENGINES . . . . . . . . . . . . . . . . . . ......2 MUFFLER
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
EXHAUST SYSTEM - GAS ENGINE . . . ......4 REMOVAL
SPECIFICATIONS 3.7L/4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . 10
TORQUE . . . . . . . . . . . . . . . . . . . . . . . ......4 5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 10
CONVERTER-CATALYTIC INSTALLATION
DESCRIPTION - CATALYTIC CONVERTER .....5 3.7L/4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . 11
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 11
3.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .5 TAILPIPE
4.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .6 REMOVAL - 5.7L ENGINE . . . . . . . . . . . . . . . . . 12
5.7L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .6 INSTALLATION - 5.7L . . . . . . . . . . . . . . . . . . . . 12
INSPECTION ..................... . . . . . .7
INSTALLATION
3.7L ENGINE . . . . . . . . . . . . . . . . . . . . ......7
11 - 2 EXHAUST SYSTEM WK

EXHAUST SYSTEM
DESCRIPTION
GAS ENGINES

WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE-
FORE, 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: Avoid application of rust prevention compounds or undercoating materials to exhaust system
floor pan heat shields. Light overspray near the edges is permitted. Application of coating will result in
excessive floor pan temperatures and objectionable fumes.

The 3.7L/4.7L exhaust system uses two catalytic converters located in the front exhaust pipe, and a single muffler/
tailpipe assembly.
WK EXHAUST SYSTEM 11 - 3

The 5.7L exhaust system uses two catalytic converters located in the front exhaust pipe, and a single muffler and
tailpipe/resonator assembly.
The front exhaust pipe/catalytic converter assembly is a hydra-form thin wall air gap design. This design is used to
reduce heat, noise and improve emissions. When replacement is required, use original equipment parts (or their
equivalent).
The exhaust manifolds are equipped with ball flange outlets to assure a tight seal and strain free connections.
The exhaust system must be properly aligned to prevent stress, leakage and body contact. If the system contacts
any body panel, it may amplify objectionable noises originating from the engine or body.
When inspecting an exhaust system, critically inspect for cracked or loose joints, stripped screw or bolt threads,
corrosion damage and worn, cracked or broken hangers. Replace all components that are badly corroded or dam-
aged. DO NOT attempt to repair.
When replacement is required, use original equipment parts (or their equivalent). This will assure proper alignment
and provide acceptable exhaust noise levels.
The basic exhaust system consists of exhaust manifold(s), exhaust pipe with oxygen sensors, catalytic converter(s),
muffler and tailpipe.
11 - 4 EXHAUST SYSTEM
DIAGNOSIS AND TESTING
EXHAUST SYSTEM - GAS ENGINE
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE
EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints.
2. Burned or blown out muffler.
3. Burned or rusted-out exhaust
pipe.
4. Exhaust pipe leaking at manifold
flange.
5. Exhaust manifold cracked or
broken.
6. Leak between exhaust manifold
and cylinder head.
7. Restriction in muffler or tailpipe.
8. Exhaust system contacting body
or chassis.
LEAKING EXHAUST GASES 1. Leaks at pipe joints.
SPECIFICATIONS
TORQUE
DESCRIPTION N·m
Front Exhaust to Manifold Nuts 25.7
Muffler-to-Catalytic Converter flange nuts 47
Steady rest bracket mounting bolts 47
WK
CORRECTION
1. Tighten flanges to specified
torque at leaking joints (Refer to 11
- EXHAUST SYSTEM -
SPECIFICATIONS).
2. 3.7L/4.7L Replace muffler/tailpipe
assembly (Refer to 11 - EXHAUST
SYSTEM/MUFFLER - REMOVAL).
5.7L Replace muffler. Check
exhaust system.
3. 3.7L/4.7L Replace muffler/tailpipe
assembly (Refer to 11 - EXHAUST
SYSTEM/MUFFLER - REMOVAL).
5.7L Replace tailpipe resonator
assembly (Refer to 11 - EXHAUST
SYSTEM/TAILPIPE - REMOVAL).
4. Tighten connection attaching nuts
(Refer to 11 - EXHAUST SYSTEM -
SPECIFICATIONS).
5. Replace exhaust manifold (Refer
to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD -
REMOVAL).
6. Tighten exhaust manifold to
cylinder head stud nuts or bolts
(Refer to 9 - ENGINE -
SPECIFICATIONS).
7. Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
8. Re-align exhaust system to clear
surrounding components.
1. Tighten flanges (Refer to 11 -
EXHAUST SYSTEM -
SPECIFICATIONS).
Ft.Lbs. In.Lbs.
19 -
35 -
35 -
WK EXHAUST SYSTEM 11 - 5

CONVERTER-CATALYTIC
DESCRIPTION - 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
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 front exhaust pipe/catalytic converter assembly

(3) is a hydra-form thin wall air gap design. This
design is used to reduce heat, noise and improve
emissions. When replacement is required, use original
equipment parts (or their equivalent).
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.

REMOVAL
3.7L ENGINE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.

1. Raise and support the vehicle.

2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 -
FRAME & BUMPERS/FRAME/REAR CROSSMEM-
BER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical con-
nectors.
5. Remove steady rest bracket mounting bolt (5) from
transmission.
6. Remove the nuts from the front exhaust pipe/cata-
lytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the
exhaust manifold.
11 - 6 EXHAUST SYSTEM WK

8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).

4.7L ENGINE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.

1. Raise and support the vehicle.

2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 -
FRAME & BUMPERS/FRAME/REAR CROSSMEM-
BER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical con-
nectors.
5. Remove steady rest bracket mounting bolt (5) from
transmission.
6. Remove the nuts from the front exhaust pipe/cata-
lytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the
exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).

5.7L ENGINE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.

1. Raise and support the vehicle.

2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove transmission crossmember (Refer to 13 -
FRAME & BUMPERS/FRAME/REAR CROSSMEM-
BER - REMOVAL).
4. Disconnect and mark oxygen sensor electrical con-
nectors.
5. Remove steady rest bracket mounting bolt (5) from
transmission.
6. Remove the nuts from the front exhaust pipe/cata-
lytic converter assembly to muffler flange.
7. Remove bolts (2) and flanged nuts (1) at the
exhaust manifold.
8. Remove the front exhaust pipe/catalytic converter assembly (3) from the vehicle.
9. Remove steady rest bracket (4) from front exhaust pipe/catalytic converter assembly (3).
WK EXHAUST SYSTEM 11 - 7

INSPECTION
Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of
overheating.
If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate
a damaged core.

INSTALLATION
3.7L ENGINE
1. Position steady rest bracket (4) onto the front
exhaust pipe/catalytic converter assembly (3).
2. Position the front exhaust pipe/catalytic converter
assembly (4) into vehicle.
3. Install the bolts (2) and nuts (1) at the front exhaust
pipe/catalytic converter assembly (3) to exhaust
manifold flange. Do not tighten.
4. Install the nuts at the front exhaust pipe/catalytic
converter assembly to muffler flange. Do not
tighten.
5. Position the exhaust pipe for proper clearance with
the frame and underbody parts. A minimum clear-
ance of 25.4 mm (1.0 in.) is required.
6. Tighten front exhaust pipe/catalytic converter
assembly to exhaust manifold bolts (2) to 25.7 N·m
(19 in. lbs.) torque.
7. Tighten the front exhaust pipe and catalytic con-
verter assembly to muffler flange nuts to 47 N·m
(35 ft. lbs.) torque.
8. Install steady rest bracket bolts. Tighten bolts to 47 N·m (35 ft. lbs.).
9. Connect oxygen sensor electrical connectors.
10. Install transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER -
INSTALLATION)
11. Lower vehicle.
12. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.
11 - 8 EXHAUST SYSTEM WK

4.7L ENGINE
1. Position steady rest bracket (4) onto the front
exhaust pipe/catalytic converter assembly (3).
2. Position the front exhaust pipe/catalytic converter
assembly (4) into vehicle.
3. Install the bolts (2) and nuts (1) at the front exhaust
pipe/catalytic converter assembly (3) to exhaust
manifold flange. Do not tighten.
4. Install the nuts at the front exhaust pipe/catalytic
converter assembly to muffler flange. Do not
tighten.
5. Position the exhaust pipe for proper clearance with
the frame and underbody parts. A minimum clear-
ance of 25.4 mm (1.0 in.) is required.
6. Tighten front exhaust pipe/catalytic converter
assembly to exhaust manifold bolts (2) to 25.7 N·m
(19 in. lbs.) torque.
7. Tighten the front exhaust pipe and catalytic con-
verter assembly to muffler flange nuts to 47 N·m
(35 ft. lbs.) torque.
8. Install steady rest bracket bolts. Tighten bolts to 47 N·m (35 ft. lbs.).
9. Connect oxygen sensor electrical connectors.
10. Install transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER -
INSTALLATION)
11. Lower vehicle.
12. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.

5.7L ENGINE
1. Position steady rest bracket (4) onto the front
exhaust pipe/catalytic converter assembly (3).
2. Position the front exhaust pipe/catalytic converter
assembly (4) into vehicle.
3. Install the bolts (2) and nuts (1) at the front exhaust
pipe/catalytic converter assembly (3) to exhaust
manifold flange. Do not tighten.
4. Install the nuts at the front exhaust pipe/catalytic
converter assembly to muffler flange. Do not
tighten.
5. Position the exhaust pipe for proper clearance with
the frame and underbody parts. A minimum clear-
ance of 25.4 mm (1.0 in.) is required.
6. Tighten front exhaust pipe/catalytic converter
assembly to exhaust manifold bolts (2) to 25.7 N·m
(19 in. lbs.) torque.
7. Tighten the front exhaust pipe and catalytic con-
verter assembly to muffler flange nuts to 47 N·m
(35 ft. lbs.) torque.
8. Install steady rest bracket bolts. Tighten bolts to 47 N·m (35 ft. lbs.).
9. Connect oxygen sensor electrical connectors.
WK EXHAUST SYSTEM 11 - 9

10. Install transmission crossmember (Refer to 13 - FRAME & BUMPERS/FRAME/REAR CROSSMEMBER -

INSTALLATION)
11. Lower vehicle.
12. Start the vehicle and inspect for exhaust leaks. Repair exhaust leaks as necessary.

MUFFLER
DESCRIPTION
All engines use a stainless steel muffler and tailpipe
assembly to control exhaust noise levels and exhaust
back pressure. The 3.7L/4.7L muffler and tailpipe are
a one piece assembly.

The 5.7L tailpipe is serviced separately.

11 - 10 EXHAUST SYSTEM WK

REMOVAL
3.7L/4.7L ENGINE
1. Raise the vehicle and support the rear of the vehi-
cle by the side rails and allow the axle to hang
free.
2. Saturate the bolts and nuts (2) with heat valve
lubricant. Allow 5 minutes for penetration.
3. Position a jackstand under the rear axle.
4. Remove RH rear shock absorber (Refer to 2 -
SUSPENSION/REAR/SHOCK - REMOVAL) and
RH side of stabilizer bar (Refer to 2 - SUSPEN-
SION/REAR/STABILIZER BAR - REMOVAL).
5. Remove the front exhaust pipe/catalytic converter
to muffler/tailpipe assembly flange nuts (2) and
ground strap (5).
6. Remove tailpipe/muffler assembly (3) from Isola-
tors.
7. Remove the muffler/tailpipe assembly (3) from
vehicle.

5.7L ENGINE
1. Raise the vehicle and support the rear of the vehi-
cle by the side rails and allow the axle to hang
free.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove muffler from isolator.
4. Remove the tailpipe/resonator to muffler assembly
flange nuts.
5. Remove the front exhaust pipe/catalytic converter
to muffler flange nuts.
6. Remove muffler from vehicle.
WK EXHAUST SYSTEM 11 - 11

INSTALLATION
3.7L/4.7L ENGINE
1. Position muffler and tailpipe assembly in vehicle.
2. Install insulators.
3. Install bolts and nuts (2) and ground strap (5) at
front exhaust pipe/catalytic converter flange (1)
4. Make sure the muffler/tailpipe assembly is correctly
positioned and the properly aligned. The minimum
clearance between components is 25mm (1 inch).
5. Tighten nuts (2) to 47 N·m (35 ft. lbs.).
6. Install RH shock absorber (Refer to 2 - SUSPEN-
SION/REAR/SHOCK - INSTALLATION) and sta-
blizer bar (Refer to 2 - SUSPENSION/REAR/
STABILIZER BAR - INSTALLATION).
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.

INSTALLATION
1. Position muffler in vehicle.
2. Install front exhaust pipe/catalytic converter to muf-
fler flange nuts. Do not tighten at this time.
3. Install tailpipe/resonator assembly to muffler flange
gasket and nuts. Do not tighten at this time.
4. Install rear insloator.
5. Make sure the muffler/tailpipe assembly is correctly
positioned and the properly aligned. The minimum
clearance between components is 25mm (1 inch).
6. Tighten flange nuts to 47 N·m (35 ft. lbs.).
7. Lower the vehicle.
8. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
11 - 12 EXHAUST SYSTEM WK

TAILPIPE
REMOVAL - 5.7L ENGINE
1. Raise the vehicle and support the rear of the vehi-
cle by the side rails and allow the axle to hang
free.
2. Saturate the bolts and nuts with heat valve lubri-
cant. Allow 5 minutes for penetration.
3. Remove rear tailpipe isolators.
4. Remove the tailpipe/resonator to muffler assembly
flange nuts.
5. Remove tailpipe and resonator assembly from
vehicle.

INSTALLATION - 5.7L
1. Position the tailpipe/resonator assembly in vehicle.
2. Install tailpipe/resonator insulators.
3. Install new gasket and tailpipe/resonator to muffler
flange nuts and bolts. Tighten to 47 N·m (35 ft.
lbs.).
4. Make sure the tailpipe/resonator assembly is cor-
rectly positioned and the properly aligned. The min-
imum clearance between components is 25mm (1
inch).
5. Lower the vehicle.
6. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.