Chrysler PT Cruiser. Manual — part 722
DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS
CONDITION
POSSIBLE CAUSES
CORRECTION
EXCESSIVE EXHAUST
NOISE (UNDER HOOD)
1. Exhaust manifold cracked or
broken.
1. Replace manifold.
2. Manifold to cylinder head leak.
2. Tighten manifold and/or replace gasket.
3. Exhaust flex joint to manifold leak.
3.Tighten fasteners or replace gasket.
4. Exhaust flex joint.
4. Replace catalytic converter assembly.
5. Pipe and shell noise from front
exhaust pipe.
5. Characteristic of single wall pipes.
EXCESSIVE EXHAUST
NOISE
1. Leaks at pipe joints.
1. Tighten or replace clamps at leaking
joints.
2. Burned, blown, or rusted out
exhaust pipe or muffler.
2. Replace muffler or exhaust pipes.
3. Restriction in muffler or tailpipe.
3. Remove restriction, if possible or replace
as necessary.
4. Catalytic converter material in
muffler.
4. Replace muffler and converter assembly.
Check fuel injection and ignition systems for
proper operation.
Fig. 1 Exhaust System
1 - FLEX PIPE
2 - CATALYTIC CONVERTER
3 - BAND CLAMP
4 - MUFFLER
5 - INTERMEDIATE PIPE
6 - BAND CLAMP
11 - 2
EXHAUST SYSTEM AND TURBOCHARGER
PT
EXHAUST SYSTEM AND TURBOCHARGER (Continued)
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB III
t and PEP
module pressure tester.
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 TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
NOTE: For Special Tool identification, (Refer to 11 -
EXHAUST SYSTEM - SPECIAL TOOLS).
(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB III
t and PEP
module. Select the available menu options on the
DRBIII
t 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 DRBIII
t. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS.
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
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)
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
EXHAUST SYSTEM ALIGNMENT
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 or loose clamps, heat
shields, insulators, and 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. Refer to (Fig. 2) for exhaust system
clearance specifications.
(1) Loosen clamps and support brackets.
(2) Align the exhaust system starting at the front,
working rearward.
(3) Tighten all clamps and brackets once align-
ment and clearances are achieved.
SPECIFICATIONS
EXHAUST SYSTEM CLEARANCE
(1) Refer to the following illustration to adjust the
exhaust system (Fig. 2).
PT
EXHAUST SYSTEM AND TURBOCHARGER
11 - 3
EXHAUST SYSTEM AND TURBOCHARGER (Continued)
Fig.
2
Exhaust
Clearance
11 - 4
EXHAUST SYSTEM AND TURBOCHARGER
PT
EXHAUST SYSTEM AND TURBOCHARGER (Continued)
TORQUE - EXHAUST SYSTEM COMPONENTS
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Fastener, Band Clamps
47
35
-
Fasteners, Catalytic Converter
to Exhaust Manifold Flange
28
-
250
Fasteners, Intermediate Pipe
Heat Shield
3.7
-
33
Fasteners, Support Brackets
(Frame Rail Mounted)
8.5
-
75
Fasteners, Support Bracket
(Rear Panel Mounted)
3.7
-
33
TORQUE - TURBOCHARGER COMPONENTS
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Fasteners, Charge Air Cooler
8
-
70
Hose Clamps, Charge Air
Cooler
1.7
-
15
Banjo Fitting, Coolant Line
37
27
-
Brass Fitting, Coolant/Oil Line
41
30
-
Flared Fitting, Coolant/Oil Line
31
23
-
Elbow
28
-
250
Elbow Support Bracket
M8 Fasteners
28
-
250
M10 Fasteners
54
40
-
Fasteners, Exhaust Manifold/
Turbocharger Assembly to
Cylinder Head
28
-
250
Fasteners, Heat Shield
28
-
250
Fasteners, Oil Return Tube
12
-
105
Turbocharger Support Bracket
54
40
-
SPECIAL TOOLS
EXHAUST SYSTEM
1 - TUNNEL HEAT SHIELD
2 - INTERMEDIATE PIPE
3 - BAND CLAMP
4 - FUEL TANK STRAP
5 - FLOOR PAN
6 - INTERMEDIATE PIPE
7 - HEAT SHIELD
8 - SPARE TIRE
9 - MUFFLER
10 - REAR FASCIA
11 - TAIL PIPE
12 - HEAT SHIELD
13 - OXYGEN SENSOR
14 - CATALYTIC CONVERTER
15 - TUNNEL HEAT SHIELD
16 - INTERMEDIATE PIPE
17 - FUEL TANK
18 - TANK STRAP
19 - SUSPENSION LINKAGE
20 - INTERMEDIATE PIPE
DRB III & PEP Module - OT-CH6010A
Back Pressure Test Adapter - CH8519
Pressure Transducer CH7063
PT
EXHAUST SYSTEM AND TURBOCHARGER
11 - 5
EXHAUST SYSTEM AND TURBOCHARGER (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст