Description: 2009 Chrysler Town & Country LX 2009 Chrysler Town & Country LX

2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
2009 ENGINE
Exhaust System - Grand Caravan, Town & Country
DESCRIPTION
GAS ENGINE
Fig. 1: Identifying Exhaust System Components - 4.0L

Courtesy of CHRYSLER LLC
1 - EXHAUST PIPE/CATALYTIC CONVERTER

2 - BAND CLAMP
3 - MUFFLER/RESONATOR
4 - ISOLATOR
The exhaust system consists of a catalytic converter, muffler and a resonator assembly. The system is serviced
in two sections; the catalytic converter and pipe, and the muffler and resonator with connecting pipe.
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Fig. 2: Identifying Exhaust System Components - 3.3/3.8L

1 - FLEX JOINT
2 - CATALYTIC CONVERTER
3 - BAND CLAMP
4 - MUFFLER/RESONATOR
5 - ISOLATOR
A band clamp is used to connect the joint between the two components. Four support hanger rods with rubber
isolators are used to support and isolate the exhaust system. A flexible joint, integral to the catalytic converter,
allows for engine movement.
DIESEL
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Monday, May 30, 2011 12:01:17 PM Page 2 © 2006 Mitchell Repair Information Company, LLC.
Fig. 3: Identifying Exhaust System Components - 2.8L Diesel

1 - DOC/PDF TO TURBOCHARGER FLANGE

2 - DOC/DPF
3 - EXHAUST PIPE
The 2.8L Diesel exhaust system consists of a combination Diesel Oxidation Catalyst (DOC)/Diesel Particulate
Filter (DPF), and a muffler and resonator assembly. The DOC/DPF is connected to the muffler and resonator by
a band clamp at the muffler and resonator inlet pipe.
DIAGNOSIS AND TESTING

EXCESSIVE NOISE
CONDITION POSSIBLE CAUSES CORRECTION

EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold.
(UNDER HOOD) broken.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket 3. Tighten fasteners or replace
leakage. gasket.
4. EGR Valve to EGR tube gasket 4. Tighten fasteners or replace
leakage. gasket.
5. EGR tube to manifold tube 5. Tighten tube nut.
leakage.
6. Exhaust flex-joint to manifold 6. Tighten joint fasteners and/or
leak. replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front 8. Characteristic of single wall
exhaust pipe. pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler 2. Replace muffler resonator
assembly or exhaust pipe. tailpipe assembly or exhaust pipe
with catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator
tailpipe assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. See
RESTRICTION CHECK.
Replace component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection
and ignition systems for proper
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operation.
DIESEL ENGINE
CAUTION: On high mileage vehicles it is normal to see some exhaust staining around
the turbocharger control rod area. This is not a sign of turbocharger
failure.
CONDITION POSSIBLE CAUSE CORRECTION

EXCESSIVE EXHAUST NOISE 1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
OR LEAKING EXHAUST joints.
GASES 2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust 3. Replace exhaust pipe.
pipe.
4. Exhaust pipe leaking at 4. Tighten/replace flange attaching
manifold flange. nuts/bolts.
5. Exhaust manifold cracked or 5. Replace exhaust manifold.
broken.
6. Leak between exhaust manifold 6. Tighten exhaust manifold to
and cylinder head. cylinder head bolts. Replace gasket
if necessary.
7. Turbocharger mounting flange 7. Remove turbocharger and
cracked. inspect. Refer to REMOVAL .
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
9. EGR pipe(s) leak Tighten bolts, Replace gasket
10. EGR assembly leak Tighten bolts, Replace gaskets
Driveability Concern - Turbo 1. Vacuum hose disconnected 1. Check connections, replace as
necessary
2. Vacuum system leaks 2. Inspect for damage, Check for
leaks, replace as necessary
3. Boost pressure solenoid filter 3. Replace the filter
clogged
RESTRICTION CHECK
Exhaust system restriction can be checked by measuring back pressure using the scan tool and PEP module
pressure 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
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rises to a high level after a short period of engine operation time.
NOTE: For Special Tool identification, see Exhaust System - Special Tools.
1. Disconnect and remove the upstream (before catalytic converter) oxygen sensor. Refer to Fuel
System/Fuel Injection/SENSOR, Oxygen - 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 pressure tester instruction manual, connect all required cables to the scan tool
and PEP module. Select the available menu options on the scan tool 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 scan tool. Back pressure should not exceed specified limit. Refer to EXHAUST BACK PRESSURE
LIMITS.
7. If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further
catalytic converter inspection procedures, see Exhaust System/CONVERTER, Catalytic - Inspection.
Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS

Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral (no load) @2000 RPM 3.45 kPa (0.5 psi)
LEAK TESTING
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.
1. Raise and support vehicle.
CAUTION: The air pressure must not exceed 4 psi, otherwise engine damage
can occur.
2. Connect Tool 8404-EC or 8404-ECT, Exhaust Cone to an adjustable air pressure regulator.
3. Attach shop air to the air pressure regulator.
4. Adjust the air pressure regulator to 4 psi
5. Insert Tool 8404-EC or 8404-ECT, Exhaust Cone into the vehicle tail pipe.
6. If the vehicle is equipped with dual exhaust, use Tool 8404-EC or 8404-ECT, Exhaust Cone with
equipped attached plug. Plug one side of the dual exhaust pipe. Pressurize the other as described.
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7. Apply a mixture of liquid dish soap and water to the following areas:
 - All welded joints from 6 inches rearward of the downstream O2 sensor forward
 - O2 sensor seal points
 - O2 sensor boss welds
 - Flange/joint connection(s)
 - Exhaust manifold to cylinder head connection(s)
 - EGR solenoid gasket base and tube seal points (if equipped)
8. Watch for the liquid/soapy water to bubble.

9. Use the following definitions to help determine if system or component repair/replacement is necessary:
 Type 1 Leak is defined as a leak where very small foam like bubbles 1mm (.039 in.) or less appear. Any
Type 1 or greater leaks found in welded joints, O2 sensor seal points or O2 sensor boss welds must be
repaired or the component must be replaced.
 Type 2 Leak is defined as a leak where larger bubbles 8mm (.031 in.) or greater appear. Any Type 2 or
greater leaks found in flange or joint connections, exhaust manifold to cylinder head connections, or EGR
gasket and tube seal points must be repaired or the components must be replaced.
Repair Required If Results At 4 Psi Reveal

Leak Location
Bubble Size:
Welded joints Type 1 - 1 mm (.039 in.) or greater
O2 Sensor seal points Type 1 - 1 mm (.039 in.) or greater
O2 Sensor boss welds Type 1 - 1 mm (.039 in.) or greater
Flange/joint connections Type 2 - 8 mm (.031 in.) or greater
Exhaust Manifold to cylinder head connections Type 2 - 8 mm (.031 in.) or greater
EGR gasket and tube seal points Type 2 - 8 mm (.031 in.) or greater
If a leak is found that matches the above definition, repair or replace the component as necessary.
Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.
INSPECTION
INSPECTION
Inspect the exhaust pipes, catalytic converters, muffler, and resonators for cracked joints, broken welds and
corrosion 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
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ADJUSTMENTS
Fig. 4: Identifying Exhaust System Alignment

1 - HANGER BRACKET TO BODY

2 - ISOLATOR
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4 - 6 MM (0.25 IN.) SPECIFICATION
A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust system
components. These noises are sometimes hard to distinguish from other chassis noises. Inspect exhaust system
for broken, damaged or loose components such as; clamps, heat shields, isolators, and hanger 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 band clamp at catalytic converter pipe to muffler/resonator assembly.

2. Align the exhaust system by inserting pipe inward or outward until specification (4), 6 mm (0.25 in.) is
achieved.
3. Tighten band clamp to 54 N.m (40 ft. lbs.).
SPECIFICATIONS
TORQUE
TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
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Band Clamp 54 40 -
Fastener, Cross-over Pipe 41 30 -
Fastener, Exhaust Manifold Flange 37 - 325
Fastener, Heat Shield (Muffler) 2.6 - 23
Fastener, Heat Shield (Toe Board) 2.6 - 23
Fastener, Heat Shield (Resonator Pipe) 2.6 - 23
Bolt, Insulator Mounting Bracket 28 - 250
Nuts, Exhaust Manifold (Diesel) 36 26 318
Refer to Engine/Manifolds/MANIFOLD, Exhaust - Installation .
Bolts, Exhaust Manifold Heat Shield (Diesel) 27.5 21 -
Bolts, Turbocharger Bracket 47 35 -
Nuts, Turbocharger Downpipe 32.5 24 -
Fitting, Turbocharger Oil Feed Line 4.7 - 41
Nuts, Turbocharger to Manifold 32.5 24 -
SPECIAL TOOLS
SPECIAL TOOLS
Fig. 5: Back Pressure Test Adapter - CH8519

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Fig. 6: Exhaust Cone Tool - 8404-ECT

Fig. 7: Pressure Transducer - CH7063

CONVERTER, CATALYTIC
DESCRIPTION
GAS ENGINE
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Fig. 8: Identifying Catalytic Converter & Related Components - Gas Engine

1 - FLEXIBLE JOINT
3 - DOWNSTREAM OXYGEN SENSOR
4 - EXHAUST PIPE
5 - MANIVERTER
6 - CROSS-UNDER PIPE
A - 3.3/3.8L ENGINE
B - 4.0L ENGINE
The 3.3/3.8L three-way catalytic converter is connected to the exhaust manifold by the use of flex joint and a
gasket. The catalytic converter outlet connects to the muffler and resonator assembly and is secured with a band
clamp. The downstream oxygen sensor is located in the catalytic converter.
The 4.0L engine uses maniverters, a combination exhaust manifold and catalytic converter. The front and rear
maniverters are connected by a cross-under pipe. The downstream oxygen sensors is located in the maniverters.
An exhaust pipe connects the cross-under pipe to the muffler and resonator assembly and is secured by a band
clamp.
DIESEL ENGINE
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2 - DOC/DPF
3 - EXHAUST PIPE
The Diesel Oxidation Catalyst (DOC) is a ceramic flow through substrate coated with a catalyst washcoat that is
integral to the DOC/Diesel Particulate Filter (DPF) assembly. The close coupled DOC treats engine exhaust
gases by converting harmful carbon monoxide, unburned hydrocarbons and other compounds into water, carbon
dioxide and heat.
OPERATION
GAS ENGINE
The three-way catalytic converter simultaneously converts three exhaust emissions into harmless gases.
Specifically, 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 a 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
"punch through."
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
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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
temperature 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 excessively 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.
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.
DIESEL ENGINE
Exhaust gases travel from the engine turbocharger through the Diesel Oxidation Catalyst (DOC) and Diesel
Particulate Filter into the exhaust system. The DOC treats the exhaust gas by converting harmful carbon
monoxide, unburned hydrocarbons and other compounds into water, carbon dioxide and heat.
The partially treated exhaust gases from the DOC flow into the catalyzed Diesel Particulate Filter (DPF) which
traps and accumulates particulate matter (soot) and further treats the exhaust gases to reduce harmful
compounds. The trapped particulate molecules will be periodically removed from the DPF through a thermal
regeneration process initiated by the engine's electronic controls.
The exhaust gases are then forced through the muffler for noise control. From the muffler the treated exhaust
gases flow through the tail pipe and out into the ambient atmosphere.
CAUTION: High engine oil level could possibly cause premature DPF failures or
excessive regeneration attempts. FOR THE DPF APPLICATION, A LEVEL
OF 10mm ABOVE THE OIL DIPSTICK'S MAX LINE IS ACCEPTABLE. If the
level exceeds the acceptable level, it is recommended to change the oil.
REMOVAL
3.3/3.8L
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Fig. 10: Disconnecting/Connecting Downstream Oxygen Sensor Electrical Connector

1 - OXYGEN SENSOR CONNECTOR

4 - ENGINE HARNESS CONNECTOR
1. Loosen clamp and disconnect the muffler and resonator assembly from catalytic converter pipe. See
Exhaust System/MUFFLER, Exhaust - Removal.
2. Disconnect downstream oxygen sensor electrical connector (1).
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Fig. 11: Removing/Installing Catalytic Converter

1 - FLAG NUT
2 - GASKET
3 - BOLT
3. Remove catalytic converter to exhaust manifold attaching bolts (3).

4. Remove catalytic converter (4) and gasket.
4.0L
For removal of the 4.0L Maniverters, refer to REMOVAL .
2.8L DIESEL
For removal of the 2.8L Diesel Oxidation Catalyst (DOC)/Diesel Particulate Filter (DPF) assembly, see
Exhaust System/FILTER, Diesel Particulate - Removal.
INSPECTION
INSPECTION
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. See 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
3.3/3.8L
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Fig. 12: Removing/Installing Catalytic Converter

1 - FLAG NUT
2 - GASKET
3 - BOLT
1. Position new gasket (2) onto the manifold flange and install catalytic converter (4). Tighten bolts (3) to 37
N.m (27 ft. lbs.).
Fig. 13: Disconnecting/Connecting Downstream Oxygen Sensor Electrical Connector

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1 - OXYGEN SENSOR CONNECTOR

4 - ENGINE HARNESS CONNECTOR
NOTE: Be careful not to twist or kink the oxygen sensor wires.
2. Install (if removed) and connect the downstream oxygen sensor electrical connector (1).
3. Install the muffler/resonator assembly. See Exhaust System/MUFFLER, Exhaust - Installation.
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.
4.0L
For installation of the 4.0L Maniverters, refer to INSTALLATION .
2.8L DIESEL
For installation of the 2.8L Diesel Oxidation Catalyst (DOC)/Diesel Particulate Filter (DPF) assembly, see
Exhaust System/FILTER, Diesel Particulate - Installation.
FILTER, DIESEL PARTICULATE

DESCRIPTION
DESCRIPTION
The diesel particulate filter (DPF) is installed for exhaust gas after-treatment. The DPF filters, stores and burns
particulate matter (soot) that is generated during the combustion process.
OPERATION
OPERATION
The NO2 molecules in the exhaust temperature range of 300 - 400°C (572 - 753°F) regenerate the Diesel
Particulate Filter (DPF), which is passive regeneration. If the passive regeneration cannot keep up with the build
up of soot in the DPF, the Engine Control Module (ECM) will actively regenerate the DPF to burn off soot.
Residue remains inside the DPF in the form of non-burnable ash. Ash comes from the oils and other materials
that are present in the soot. Ash is not eliminated by the regeneration cycle. Excessive ash accumulation
requires replacement of the DPF. The DPF uses a silicon carbide wall-flow monolith with a platinum coating to
trap particulates. The monolith contains a large number of square parallel channels, which run in the axial
direction and are separated by thin porous walls. The channels are alternatively open at one end, and plugged at
the other. The exhaust gases flow through the walls and escape through the pores in the wall material.
Particulates, however, are too large to escape and are trapped in the monolith walls. The ECM starts the
regeneration of the DPF if the soot load exceeds a mapped value. The ECM determines the load condition of the
DPF based upon the engine operating points and the exhaust gas pressure upstream and downstream of the DPF.
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A pressure differential sensor provides the pressure input to the ECM. During the regeneration process, the
ECM raises the temperature in the DPF to burn off soot accumulated. Under normal operation, the engine does
not produce enough heat to oxidize the soot in the DPF. This process requires temperatures above 550°C (1,022
°F). The ECM calculates the ash mass stored in the DPF by using the total fuel consumption, which has a strong
correlation with oil consumption.
DIAGNOSIS AND TESTING
DIESEL PARTICULATE FILTER (DPF)
The Engine Control Module (ECM) monitors the soot load in the diesel particulate filter (DPF). Under normal
operating conditions the DPF is self cleaning, where the accumulated soot is converted to ash. Under light load
operating conditions the ECM will set a DTC if it detects that the soot level has exceeded the normal desoot
trigger threshold by a sufficient amount to indicate that the driver intervention is required. If the MIL light
comes on, refer to DIAGNOSIS AND TESTING and follow the procedure to retrieve the code.
OIL DILUTION RESET PROCEDURE
For vehicles built in 2008 and later equipped with a Diesel Particulate Filter (DPF), a manual oil dilution reset
procedure must be carried out anytime the engine oil is changed.
1. Turn key on to last key position (do not start the engine).
2. Completely press and release the accelerator pedal three times in succession. The accelerator pedal
must be completely pressed and released 3 times within 5 seconds.
3. To verify that the procedure is successful, refer to DIAGNOSIS AND TESTING .
REMOVAL
REMOVAL
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2 - DOC/DPF
3 - EXHAUST PIPE
NOTE: Any time the DPF is replaced, it is necessary to reset the ash/soot data stored in
the ECM by using the dedicated SCAN TOOL routine.
1. Raise and support the vehicle.

2. Disconnect the pressure differential tubing.
3. Disconnect the oxygen sensor from the DOC/DPF.
4. Disconnect the exhaust pipe (3) at the exhaust pipe to DOC/DPF flange. Discard gasket.
5. Remove the DOC/DPF (2) from exhaust manifold.
6. Remove the DOC/DPF (2) from the exhaust hangers.
7. Remove the DOC/DPF (2) from vehicle.
INSTALLATION
INSTALLATION


2 - DOC/DPF
3 - EXHAUST PIPE
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1. Position the DOC/DPF (2) to the exhaust hangers.

2. Using a new gasket, position DPF (2) to exhaust manifold.
3. Tighten flange nuts to 34 N.m (25 ft. lbs.).
4. Using a new gasket, position DPF (2) to exhaust pipe (3) flange.
5. Tighten flange nuts to 34 N.m (25 ft. lbs.).
6. Install the oxygen sensor to the DOC/DPF. Tighten the sensor to 34 N.m (25 ft. lbs.).
7. Install the pressure differential tubing.
8. Lower the vehicle.
9. Connect negative battery cable.
MUFFLER, EXHAUST
REMOVAL
REMOVAL
Fig. 16: Removing/Installing Exhaust System Components

1 - BAND CLAMP
2 - CATALYTIC CONVERTER PIPE
NOTE: To provide removal clearance between muffler/resonator pipe and rear axle
parts, the rear suspension must be relieved of all body weight.
NOTE: When replacement is required on any component of the exhaust system, it is

important that original equipment parts (or equivalent) be used.
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1. Raise and support vehicle.

2. Apply a penetrating oil to clamp nuts of component requiring removal.
3. Loosen the band clamp (1) at the muffler to converter pipe connection (2).
4. Separate muffler pipe from converter pipe (2).
CAUTION: Do not use any tools to remove the rubber isolators, remove by hand
only. Soapy water or silicone based lubricant spray may be used to
assist removal/installation of isolators. DO NOT use a petroleum
based lubricant on the isolators, as damage to the rubber material
can occur.
5. Remove support isolators from muffler/resonator assembly supports.

6. Remove muffler/resonator assembly by moving assembly forward and guiding the resonator through the
rear axle- to- body opening.
7. Clean ends of pipes or muffler to assure mating of all parts. Discard broken or worn insulators, rusted
clamps, supports and attaching parts.
INSTALLATION
INSTALLATION
Fig. 17: Removing/Installing Exhaust System Components

1 - BAND CLAMP
2 - CATALYTIC CONVERTER PIPE
1. Position the muffler/resonator assembly into vehicle by guiding resonator between the rear axle and body.
2. Connect the muffler/resonator assembly into the catalytic converter pipe (2). Do not tighten band clamp .
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3. Install muffler/resonator assembly into isolators.
CAUTION: Band clamps should never be tightened such that the two sides of
the clamps are bottomed 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.
4. Install band clamp (1). Tighten the band clamp to 55 N.m (40 ft. lbs.).
PIPE, EXHAUST CROSSOVER

REMOVAL
REMOVAL
3.3/3.8L
Fig. 18: Removing/Installing Exhaust Cross-Over Pipe

1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
1. Disconnect negative cable from battery.

2. Remove the fasteners (2 and 4) attaching the left bank manifold connection to cross-over pipe (1).
3. Raise vehicle and remove the left front wheel.
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4. Access the lower right bank pipe connection fastener through the left front wheel opening using a long
ratchet extension. Loosen and remove the lower fastener.
5. Remove the upper right bank pipe connection fastener by accessing though the catalytic converter floor
pan tunnel.
6. Lower the vehicle.
7. Remove the cross-over pipe.
8. Remove gaskets and discard.
INSTALLATION
INSTALLATION
3.3/3.8L
Fig. 19: Removing/Installing Exhaust Cross-Over Pipe

1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
1. Position cross-over pipe (1) to the manifold connections.

2. Position new gasket (3) on left bank (front) pipe connection and loosely install fasteners.
3. Raise the vehicle.
4. Position new gasket on the right bank pipe connection and install fasteners.
5. Tighten right bank upper fastener to 41 N.m (30 ft. lbs.).
6. Tighten right bank lower fastener to 41 N.m (30 ft. lbs.) using a long ratchet extension accessing through
the left wheel opening.
7. Install the left front wheel and lower vehicle.
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8. Tighten the left bank pipe connection fasteners to 41 N.m (30 ft. lbs.).
PIPE, EXHAUST CROSSUNDER

REMOVAL
REMOVAL
For removal of the 4.0L Cross-under pipe, refer to REMOVAL .
INSTALLATION
INSTALLATION
For installation of the 4.0L Cross-under pipe. Refer to INSTALLATION .
RESONATOR, EXHAUST
REMOVAL
REMOVAL
The resonator is part of the muffler/resonator assembly. For removal, see Exhaust System/MUFFLER,
Exhaust - Removal.
INSTALLATION
INSTALLATION
The resonator is part of the muffler/resonator assembly. For installation, see Exhaust System/MUFFLER,
Exhaust - Removal.
SENSOR, DIFFERENTIAL PRESSURE

DESCRIPTION
DESCRIPTION
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Fig. 20: Locating Differential Pressure Sensor - 2.8L Diesel

The differential pressure sensor (4) is mounted to a bracket located near the coolant overflow bottle. The
differential pressure sensor generates a signal based on the flow rate of exhaust gas through the diesel
particulate filter. As diesel soot accumulates in the diesel particulate filter, a higher pressure will be present in
the particulate filter inlet. A lower pressure will be present at the particulate outlet. The ECM uses the
differential pressure sensor to detect the pressure difference between the diesel particulate inlet and outlet.
When the ECM senses that the soot level in the particulate filter has reached a specified threshold, the ECM
performs a particulate filter regeneration cycle to clear soot from the diesel particulate filter.
REMOVAL
REMOVAL
NOTE: Any time the Exhaust Pressure Differential Sensor is replaced or the hose has
been repaired, it is necessary to reset the offset value stored in the ECM by
using the dedicated SCANTOOL routine.
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1. Disconnect the differential pressure sensor hoses (2) and (3).

2. Disconnect the harness connector (1).
Fig. 22: Removing/Installing Differential Pressure Sensor

3. Release the clips (1) and (2), and remove the differential pressure sensor (3).
INSTALLATION
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INSTALLATION
Fig. 23: Removing/Installing Differential Pressure Sensor

NOTE: Any time the Exhaust Pressure Differential Sensor is replaced or the hose has
been repaired, it is necessary to reset the offset value stored in the ECM by
using the dedicated SCANTOOL routine.
1. Install the differential pressure sensor (3).

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2. Reconnect the harness connector (1).

3. Reconnect the differential pressure sensor hoses (2) and (3).
SENSOR, EXHAUST TEMPERATURE

DESCRIPTION
DESCRIPTION
Fig. 25: Locating Exhaust Temperature Sensor - 2.8L Diesel

The diesel exhaust temperature sensor (3) is located on the side of the diesel particulate filter. During a
particulate filter regeneration cycle, the ECM uses the exhaust temperature sensor to monitor the temperature of
the diesel particulate filter.
REMOVAL
REMOVAL
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1. Disconnect the harness connector (1).

2. Remove the exhaust temperature sensor (3).
INSTALLATION
INSTALLATION

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1. Install the exhaust temperature sensor (3). Tighten to 40 Nm (29 ft. lbs.).
2. Reconnect the harness connector (1).
SHIELD, HEAT
DESCRIPTION
DESCRIPTION
Fig. 28: Identifying Heat Shields

1 - NUT
2 - 2nd ROW TUB HEAT SHIELD
3 - 2nd ROW FLOOR TUB HEAT SHIELD
4 - RETAINER
5 - MUFFLER HEAT SHIELD
6 - KICK UP HEAT SHIELD
The exhaust system heat shields, attached to the under body of the vehicle.
OPERATION
OPERATION
Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan
heat shields on vehicles so equipped. Light over spray near the edges is permitted. Application of coating
will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and
objectionable fumes.
Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed
steve
near the catalytic converter and exhaust system.
REMOVAL
REMOVAL

1 - NUT
4 - RETAINER
1. Raise vehicle on hoist.

2. Remove fasteners attaching applicable heat shield.
3. Remove heat shield(s).
INSTALLATION
INSTALLATION
steve

1 - NUT
4 - RETAINER
1. Position heat shield(s) to underbody.

2. Install heat shield fasteners and tighten to 2.6 N.m (23 in. lbs.).
3. Lower vehicle.
steve

Description: 2009 Chrysler Town & Country LX 2009 Chrysler Town & Country LX

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Description: 2009 Chrysler Town & Country LX 2009 Chrysler Town & Country LX

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2009 Chrysler Town & Country LX

2009 ENGINE Exhaust System - Grand Caravan, Town & Country

Exhaust System - Grand Caravan, Town & Country

Fig. 1: Identifying Exhaust System Components - 4.0L

1 - EXHAUST PIPE/CATALYTIC CONVERTER

Fig. 2: Identifying Exhaust System Components - 3.3/3.8L

Fig. 3: Identifying Exhaust System Components - 2.8L Diesel

1 - DOC/PDF TO TURBOCHARGER FLANGE

DIAGNOSIS AND TESTING

CONDITION POSSIBLE CAUSES CORRECTION

CONDITION POSSIBLE CAUSE CORRECTION

rises to a high level after a short period of engine operation time.

EXHAUST BACK PRESSURE LIMITS

1. Raise and support vehicle.

 - O2 sensor seal points

 - O2 sensor boss welds

 - Exhaust manifold to cylinder head connection(s)

8. Watch for the liquid/soapy water to bubble.

Repair Required If Results At 4 Psi Reveal

Fig. 4: Identifying Exhaust System Alignment

1 - HANGER BRACKET TO BODY

Perform the following procedures to align the exhaust system:

1. Loosen band clamp at catalytic converter pipe to muffler/resonator assembly.

Fig. 5: Back Pressure Test Adapter - CH8519

Fig. 6: Exhaust Cone Tool - 8404-ECT

Fig. 7: Pressure Transducer - CH7063

Fig. 8: Identifying Catalytic Converter & Related Components - Gas Engine

Fig. 9: Identifying Exhaust System Components - 2.8L Diesel

1 - DOC/PDF TO TURBOCHARGER FLANGE

Fig. 10: Disconnecting/Connecting Downstream Oxygen Sensor Electrical Connector

1 - OXYGEN SENSOR CONNECTOR

Fig. 11: Removing/Installing Catalytic Converter

3. Remove catalytic converter to exhaust manifold attaching bolts (3).

For removal of the 4.0L Maniverters, refer to REMOVAL .

Fig. 12: Removing/Installing Catalytic Converter

Fig. 13: Disconnecting/Connecting Downstream Oxygen Sensor Electrical Connector

1 - OXYGEN SENSOR CONNECTOR

NOTE: Be careful not to twist or kink the oxygen sensor wires.

For installation of the 4.0L Maniverters, refer to INSTALLATION .

FILTER, DIESEL PARTICULATE

DIAGNOSIS AND TESTING

DIESEL PARTICULATE FILTER (DPF)

OIL DILUTION RESET PROCEDURE

Fig. 14: Identifying Exhaust System Components - 2.8L Diesel

1 - DOC/PDF TO TURBOCHARGER FLANGE

1. Raise and support the vehicle.

Fig. 15: Identifying Exhaust System Components - 2.8L Diesel

1 - DOC/PDF TO TURBOCHARGER FLANGE

1. Position the DOC/DPF (2) to the exhaust hangers.

Fig. 16: Removing/Installing Exhaust System Components

NOTE: When replacement is required on any component of the exhaust system, it is

1. Raise and support vehicle.

5. Remove support isolators from muffler/resonator assembly supports.

Fig. 17: Removing/Installing Exhaust System Components

3. Install muffler/resonator assembly into isolators.

PIPE, EXHAUST CROSSOVER

Fig. 18: Removing/Installing Exhaust Cross-Over Pipe

1. Disconnect negative cable from battery.

Fig. 19: Removing/Installing Exhaust Cross-Over Pipe

1. Position cross-over pipe (1) to the manifold connections.

PIPE, EXHAUST CROSSUNDER

For removal of the 4.0L Cross-under pipe, refer to REMOVAL .

For installation of the 4.0L Cross-under pipe. Refer to INSTALLATION .