Professional Documents
Culture Documents
2009 ENGINE
DESCRIPTION
GAS ENGINE
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.
2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.
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.
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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Monday, May 30, 2011 12:01:17 PM Page 4 © 2006 Mitchell Repair Information Company, LLC.
2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.
LEAK TESTING
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: 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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Monday, May 30, 2011 12:01:17 PM Page 5 © 2006 Mitchell Repair Information Company, LLC.
2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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
- Flange/joint connection(s)
- EGR solenoid gasket base and tube seal points (if equipped)
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.
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
ADJUSTMENTS
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.
SPECIFICATIONS
TORQUE
TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
CONVERTER, CATALYTIC
DESCRIPTION
GAS ENGINE
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
1 - FLEXIBLE JOINT
2 - CATALYTIC CONVERTER
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
4.0L
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
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. 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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
1. Position new gasket (2) onto the manifold flange and install catalytic converter (4). Tighten bolts (3) to 37
N.m (27 ft. lbs.).
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
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.
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.
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.
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.
INSTALLATION
INSTALLATION
MUFFLER, EXHAUST
REMOVAL
REMOVAL
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.
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.
INSTALLATION
INSTALLATION
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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.).
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.
REMOVAL
3.3/3.8L
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
8. Tighten the left bank pipe connection fasteners to 41 N.m (30 ft. lbs.).
9. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
10. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
REMOVAL
INSTALLATION
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.
DESCRIPTION
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
3. Release the clips (1) and (2), and remove the differential pressure sensor (3).
INSTALLATION
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
INSTALLATION
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.
DESCRIPTION
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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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
INSTALLATION
INSTALLATION
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
1. Install the exhaust temperature sensor (3). Tighten to 40 Nm (29 ft. lbs.).
2. Reconnect the harness connector (1).
SHIELD, HEAT
DESCRIPTION
DESCRIPTION
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
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
REMOVAL
REMOVAL
1 - NUT
4 - RETAINER
2 - 2nd ROW TUB HEAT SHIELD
5 - MUFFLER HEAT SHIELD
3 - 2nd ROW FLOOR TUB HEAT SHIELD
6 - KICK UP HEAT SHIELD
INSTALLATION
INSTALLATION
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2009 Chrysler Town & Country LX
2009 ENGINE Exhaust System - Grand Caravan, Town & Country
1 - NUT
4 - RETAINER
2 - 2nd ROW TUB HEAT SHIELD
5 - MUFFLER HEAT SHIELD
3 - 2nd ROW FLOOR TUB HEAT SHIELD
6 - KICK UP HEAT SHIELD
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