I had a shop pull the cat and muffler and put in a summit street muffler awhile back.
I ve noticed some noise and exhaust smell coming out of the engine compartment. Pulled the resovoir and heat shield and saw a gap in the connection. But, the down pipe and the tubo Don t overlap in a male/female connection. It is a face to face match. Doesn t seem right to me. Maybe the shop used a different down pipe. Should t the fittings overlap?

Not overlap, they meet face to face.
The V-band clamp holds them together very tightly.

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U.S. Army Retired

^What he said, pretty much every turbo vehicle has a flat face to face connection with a v-band clamp. As long as the faces are even and flat against each other they will seal.


And i highly doubt they used a different downpipe as i don't think there is a single aftermarket downpipe available. If i were you i'd crawl under it to make sure all the connections and clamps are tight, and look for leaks. Leaks should be easy to spot since there will be soot visible. Also look behind the engine to see if the EGR tube is broke or cracked, again any soot means there is a leak.

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Jimmy
2005 Liberty CRD, 120k miles, tuned, cat delete, Mishimoto hoses, EGR/FCV delete with Euro intake

1997 F-250 ECLB 7.3/E4OD/4wd, 215k miles: FFD 250/200%'s, Swamps IDM, built trans. Tuned by me

2001 F-450 crew cab, XLT ZF-6 7.3: 6637, shimmed 910's, in-tank mods, PHP tunes

Ok, tks

Also, I had an opening in the joint, so the shop did not properly install. I had removed the EGR pipe years ago before the weeks 101. I cut the pipe, squashed the end and welded it up.
Thought maybe something went awry in that mod. So it turned out to be the down pipe. I ve had it off before when I was doing the head job. I come from the donut era.
Again TKS.

Hey Flash,

Are these v clamps 2.5inches? You mentioned very tightly but FSM say 19ft pound which doesn't seem very tight at all.

Cheers

Chris

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2006 CRD Jeep Liberty / Cherokee - Weeks Stage 1 & 2, GDE Eco Tune, Carter In-Tank Fuel Pump & Provent 200.

The V shape in the clamp squeezes the flanges together very tightly. A large amount of torque does not need to be applied to the fastener for this to happen.

I just had this problem. It is easiest to loosen up the exhaust down pipe first and then move it into position, tighten the clamp and then tighten exhaust down pipe back down.
For loosening the exhaust downpipe crawl under the jeep look for the exhaust rubber hangers/v bracket (I believe) it is two- 13mm on top (you will have to feel around for it).

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2005 Liberty CRD, 245/75R16, OME CRD Springs front, OME HD rear

Thanks all. Amazing what a difference a tighten exhaust clamp does....mysterious rattle....gone!!

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2006 CRD Jeep Liberty / Cherokee - Weeks Stage 1 & 2, GDE Eco Tune, Carter In-Tank Fuel Pump & Provent 200.