BRExhaust Replacement Exhaust System Kit 106-0047 User Manual

1. Introduction and Overview

This manual provides detailed instructions for the installation, operation, and maintenance of your BRExhaust Replacement Exhaust System Kit, model 106-0047. This kit is designed as a direct-fit replacement for the exhaust systems in 2008-2012 Jeep Liberty and 2007-2011 Dodge Nitro vehicles equipped with a 3.7L engine. Please read this manual thoroughly before beginning installation to ensure proper procedure and safety.

2. Product Features

• Complete Mandrel-Bent Replacement: All parts from behind or near the last catalytic converter are included, offering long-lasting, high corrosion resistance and durability.
• Bolt-On, Multi-Piece Design: Engineered for smooth and easy DIY installation around obstructions, ensuring quality fitment and function without requiring fabrication.
• Comprehensive Kit: All necessary components, gaskets, clamps, and hardware are included in a single protective box.
• Emissions Compliant: Designed to leave all emissions equipment intact, maintaining compliance with regulations.
• Warranty: Backed by a two-year, unlimited mileage warranty.

3. Package Contents

Your BRExhaust Replacement Exhaust System Kit 106-0047 includes the following components:

• Muffler assembly
• Intermediate pipe(s)
• Tailpipe assembly
• Hangers (integrated or separate as required)
• Gaskets
• Clamps (e.g., 4 x 2.5-inch U-Bolt Clamps)
• All necessary hardware for installation

Figure 3.1: Exploded view of the BRExhaust Replacement Exhaust System Kit components, showing the muffler, pipes, and clamps.

Figure 3.2: All components of the BRExhaust kit are packaged together in one box for convenience.

Figure 3.3: BRExhaust kits are supplied as a single SKU, simplifying ordering and ensuring all required parts are included.

4. Safety Information

Working on vehicle exhaust systems can be hazardous. Always follow these safety precautions:

• Ensure the vehicle is securely supported on jack stands or a lift. Never rely solely on a jack.
• Allow the exhaust system to cool completely before working on it to prevent burns.
• Wear appropriate personal protective equipment, including safety glasses, gloves, and hearing protection.
• Work in a well-ventilated area.
• Use proper tools for the job.
• If you are unsure about any step, consult a qualified mechanic.

5. Installation Instructions

This BRExhaust kit is designed for a bolt-on installation. While specific steps may vary slightly by vehicle, the general procedure is as follows:

5.1. Preparation

1. Park the vehicle on a level surface and engage the parking brake.
2. Raise the vehicle using a lift or jack stands, ensuring it is stable and secure.
3. Allow the existing exhaust system to cool completely.
4. Apply penetrating oil to all bolts, nuts, and hangers that will be removed.

5.2. Removal of Old Exhaust System

1. Locate and disconnect any oxygen sensors if present.
2. Unbolt the exhaust system from the catalytic converter(s) or other connection points.
3. Carefully remove the exhaust system from its hangers. It may be necessary to cut the old system into sections for easier removal, especially if it is a single-piece design.

5.3. Installation of New Exhaust System

Figure 5.1: The BRExhaust kit is designed for ease of installation, often suitable for DIY enthusiasts.

Figure 5.2: The multi-piece design allows for easier maneuvering and installation around vehicle components.

Figure 5.3: The BRExhaust multi-piece design simplifies installation compared to traditional one-piece systems.

1. Begin by installing the front-most section of the new exhaust system, connecting it to the catalytic converter(s) or existing front pipe. Do not fully tighten bolts yet.
2. Attach the intermediate pipe(s) and muffler assembly, ensuring all components align with the vehicle's hangers.
3. Install the tailpipe assembly, ensuring proper clearance from the vehicle's undercarriage and suspension components.
4. Connect any oxygen sensors that were removed.
5. Once all components are in place and aligned, gradually tighten all clamps and bolts, working from front to back. Ensure all connections are secure and leak-free.
6. Double-check all clearances and ensure no part of the exhaust system is touching the vehicle frame or other components.

5.4. Post-Installation Check

1. Start the vehicle and listen for any exhaust leaks. Leaks can often be identified by a hissing sound.
2. If leaks are detected, tighten the corresponding clamps or connections. If leaks persist, disassemble and reassemble the affected section, ensuring gaskets are properly seated.
3. Turn off the vehicle and allow the system to cool before lowering it.

6. Operation

The BRExhaust Replacement Exhaust System operates passively as part of your vehicle's emission control and sound dampening system. No user interaction is required for its operation.

During the first few driving cycles, you may notice a slight odor as protective coatings on the new exhaust components burn off. This is normal and will dissipate.

7. Maintenance

Regular maintenance of your exhaust system helps ensure its longevity and proper function:

• Periodic Inspection: Annually or during routine vehicle service, inspect the entire exhaust system for signs of damage, corrosion, loose connections, or leaks.
• Check Hangers: Ensure all exhaust hangers are intact and securely holding the system in place. Replace any worn or broken hangers.
• Tighten Clamps/Bolts: Over time, vibrations can loosen clamps and bolts. Periodically check and tighten them as needed.
• Address Damage Promptly: Any dents, cracks, or holes should be addressed immediately by a qualified technician to prevent further damage and maintain emissions compliance.

8. Troubleshooting

If you experience issues with your exhaust system, consider the following common problems and solutions:

• Loud Noises or Rattling:
  • Check for loose clamps or bolts. Tighten as necessary.
  • Inspect hangers for wear or breakage, which can cause the system to sag or hit the vehicle.
  • Look for contact points between the exhaust pipes and the vehicle's frame or other components. Adjust alignment if needed.
• Hissing or Puffing Sounds (Exhaust Leaks):
  • Inspect all connections and welds for cracks or gaps.
  • Ensure gaskets are properly seated and not damaged.
  • Tighten all clamps and bolts.
• Decreased Engine Performance or Fuel Economy:
  • While less common with a new system, severe exhaust leaks can affect engine back pressure and oxygen sensor readings. Check for leaks as described above.
  • If issues persist, consult a professional mechanic as the problem may not be directly related to the exhaust system itself.

9. Specifications

10. Warranty and Support

Your BRExhaust Replacement Exhaust System Kit 106-0047 is covered by a two-year, unlimited mileage warranty. This warranty covers defects in materials and workmanship under normal use and service.

For warranty claims, technical support, or inquiries regarding your product, please contact BRExhaust customer service through their official website or authorized distributors. Please have your product model number (106-0047) and proof of purchase available.