Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 535
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.
INSTALLATION - EXHAUST SYSTEM
NOTE: Always work from the front to rear of
exhaust
system
when
aligning
and
tightening
exhaust system components.
(1) Loosely install fasteners that attach exhaust
system to exhaust manifold (2.0L/2.4L)/cross-under
pipe (2.7L).
(2) Install support isolators to muffler supports.
(3) Align exhaust system to maintain position and
proper clearance with underbody parts. All support
isolators should have equal load on them. Tighten
fasteners that attach exhaust system to exhaust
manifold (2.0L/2.4L)/cross-under pipe (2.7L) to 28
N·m (250 in. lbs.).
(4) Vehicles
equipped
with
2.0L/2.4L
engines,
reconnect the downstream oxygen sensor connector.
(5) Connect ground strap to muffler.
(6) Lower vehicle.
(7) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(8) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
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 or loose clamps, heat
shields, isolators, and brackets. Replace or tighten as
necessary. It is important that exhaust system clear-
ances and alignment be maintained.
Perform the following procedures to align the
exhaust system:
(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
TORQUE
DESCRIPTION
N·m
Ft.
Lbs.
In.
Lbs.
Band Clamps—Fastener
54
40
—
Body Heat Shield—Fasteners
5
—
40
Catalytic Converter to Exhaust
Manifold Flange—Fasteners
28
—
250
Cross-Under Pipe —Fasteners (2.7L)
28
—
250
SPECIAL TOOLS
EXHAUST SYSTEM
DRB III & PEP Module - OT-CH6010A
Back Pressure Test Adapter - CH8519
Pressure Transducer CH7063
JR
EXHAUST SYSTEM
11 - 5
EXHAUST SYSTEM (Continued)
CATALYTIC CONVERTER -
2.0L/2.4L
DESCRIPTION
The under-floor, three-way catalytic converter inlet
is connected to the exhaust manifold by use of a flex
joint and gasket. The outlet connects to the exhaust
system.
CAUTION: When servicing, care must be exercised
not to dent or bend the bellows or bellows cover of
the flex-joint. Should this occur, the flex-joint will
eventually fail and require the catalytic converter be
replaced.
An exhaust flex-joint coupling (Fig. 4) is used to
secure the catalytic converter to the engine manifold.
The exhaust flex-joint is welded to the catalytic
converter.
OPERATION
The three-way catalytic converter simultaneously
converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are con-
verted into water (H2O) and carbon dioxide (CO2).
Oxides of Nitrogen (NOx) are converted into elemen-
tal Nitrogen (N) and water. The three-way catalyst is
most efficient in converting HC, CO and NOx at the
stoichiometric 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
9punch through.9
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 some-
what related to proper operation, oxygen storage can
be used as an indicator of 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, caus-
ing 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, if exhaust system is equipped with a
catalytic converter. 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 exces-
sively 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.
REMOVAL
NOTE: In the following procedure it is not neces-
sary to separate the muffler/pipe assembly from the
resonator/pipe
assembly.
They
can
both
be
removed as an assembly.
Fig. 4 FLEX-JOINT COUPLING - TYPICAL
1 - BELLOWS
2 - COVER
3 - FLANGE
11 - 6
EXHAUST SYSTEM
JR
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.
(1) Raise vehicle on hoist and apply penetrating oil
to resonator/pipe assembly band clamp, and the fas-
teners that connect the catalytic converter to the
exhaust manifold.
(2) Remove ground strap from muffler.
(3) Loosen band clamp for resonator/pipe assembly.
CAUTION: Do not use any tools to remove the rub-
ber 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.
(4) Remove support isolators from muffler sup-
ports.
(5) Remove resonator/pipe and muffler/pipe as an
assembly.
(6) Disconnect downstream oxygen sensor connec-
tor.
(7) Remove fasteners that attach catalytic con-
verter to the exhaust manifold. Remove catalytic con-
verter from vehicle.
(8) Remove and discard gasket.
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE 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 CON-
VERTER. 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.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
flashlight. Inspect element for cracked or melted sub-
strate.
NOTE: Before replacing a catalytic converter, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
NOTE: Always work from the front to rear of
exhaust
system
when
aligning
and
tightening
exhaust system components.
(1) Clean manifold to converter sealing surfaces.
(2) Position new gasket on exhaust manifold.
NOTE: If catalytic converter is being replaced,
transfer downstream oxygen sensor to new con-
verter.
(3) Loosely attach catalytic converter to exhaust
manifold.
(4) Loosely install resonator/pipe and muffler/pipe
assembly to catalytic converter outlet pipe.
(5) Install support isolators to muffler supports.
(6) Align exhaust system to maintain position and
proper clearance with underbody parts. All support
isolators should have equal load on them. Tighten
fasteners attaching catalytic converter to exhaust
manifold to 28 N·m (250 in. lbs.).
(7) Tighten resonator/pipe assembly band clamp to
54 N·m (40 ft. lbs.).
(8) Connect ground strap to muffler.
(9) Lower vehicle.
(10) Start the engine and inspect for exhaust
leaks. Repair exhaust leaks as necessary.
(11) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
JR
EXHAUST SYSTEM
11 - 7
CATALYTIC CONVERTER - 2.0L/2.4L (Continued)
CATALYTIC CONVERTER -
FRONT - 2.7L
REMOVAL
(1) Disconnect negative battery cable.
(2) Disconnect upstream oxygen sensor connector.
(3) Remove 3 converter attaching nuts that are
visible from the engine compartment (Fig. 5).
(4) Raise vehicle on hoist.
(5) Remove exhaust cross-under pipe (Refer to 11 -
EXHAUST
SYSTEM/CROSS-UNDER
PIPE
-
REMOVAL).
(6) Remove remaining bolt attaching converter to
exhaust manifold.
(7) Remove catalytic converter.
(8) Remove and discard gasket.
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERA-
TURE 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 CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
Fig. 5 CATALYTIC CONVERTER - FRONT 2.7L
1 - STUD
2 - CATALYTIC CONVERTER
3 - GASKET
4 - HEAT SHIELD
5 - NUT
11 - 8
EXHAUST SYSTEM
JR
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