Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 537
(5) Remove muffler/pipe assembly from resonator
pipe.
NOTE: Band clamps are spot welded to exhaust
system. If a band clamp must be replaced, the spot
weld must be ground off the exhaust pipe.
NOTE: When replacement is required on any com-
ponent of the exhaust system, it is most important
that original equipment parts (or their equivalent)
be used for the following reasons:
• To insure proper alignment with other parts in
the system.
• Provide acceptable exhaust noise levels and does
not change exhaust system back pressure that could
affect emissions and performance.
INSTALLATION
NOTE: Always work from the front to rear of
exhaust
system
when
aligning
and
tightening
exhaust system components.
(1) Loosely install muffler/pipe assembly onto res-
onator pipe.
(2) Install support isolators to muffler supports.
(3) Align muffler/pipe assembly to maintain posi-
tion and proper clearance with underbody parts. All
support isolators should have equal load on them.
Tighten band clamp to 54 N·m (40 ft. lbs.).
(4) Connect ground strap to muffler.
(5) Lower vehicle.
(6) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(7) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
RESONATOR/PIPE ASSEMBLY
REMOVAL
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 band clamps of components being removed (Fig. 1).
(2) Remove muffler/pipe assembly (Refer to 11 -
EXHAUST SYSTEM/MUFFLER - REMOVAL).
(3) Loosen band clamp for resonator/pipe assembly.
(4) Remove resonator/pipe assembly.
NOTE: Band clamps are spot welded to exhaust
system. If a band clamp must be replaced, the spot
weld must be ground off the exhaust pipe.
NOTE: When replacement is required on any com-
ponent of the exhaust system, it is most important
that original equipment parts (or their equivalent)
be used for the following reasons:
• To insure proper alignment with other parts in
the system.
• Provide acceptable exhaust noise levels and does
not change exhaust system back pressure that could
affect emissions and performance.
INSTALLATION
NOTE: Always work from the front to rear of
exhaust
system
when
aligning
and
tightening
exhaust system components.
(1) Loosely install resonator/pipe assembly and
muffler/pipe assembly.
(2) Install support isolators to muffler supports.
(3) Align resonator/pipe assembly and muffler/pipe
assembly to maintain position and proper clearance
with underbody parts. All support isolators should
have equal load on them. Tighten resonator/pipe
assembly band clamp to 54 N·m (40 ft. lbs.).
(4) Tighten muffler/pipe assembly band clamp to
54 N·m (40 ft. lbs.).
(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.
JR
EXHAUST SYSTEM
11 - 13
MUFFLER/PIPE ASSEMBLY (Continued)
HEAT SHIELDS
DESCRIPTION
The exhaust system heat shields are attached to
the under body of the vehicle (Fig. 8).
OPERATION
Heat shields are needed to protect both the vehicle
and the environment from the high temperatures
developed near the catalytic converter.
Avoid application of rust prevention com-
pounds or undercoating materials to exhaust
system
floor
pan
heat
shields
on
cars
so
equipped. Light over spray near the edges is
permitted. Application of coating will greatly
reduce the efficiency of the heat shields result-
ing in excessive floor pan temperatures and
objectionable fumes.
Fig. 8 Heat Shields
1 - GROUND STRAP
2 - MUFFLER
3 - HEAT SHIELD
4 - RESONATOR HEAT SHIELD
11 - 14
EXHAUST SYSTEM
JR
FRAME & BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS
. . . . . . . . . . . . . . . 1
FRONT FASCIA
. . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . 2
REAR BUMPER REINFORCEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR FASCIA
. . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . . . . 5
FRAME
SPECIFICATIONS - FRAME DIMENSIONS
FRONT SUSPENSION CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR SUSPENSION CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT TOW HOOK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
. . . . . . . . . . . . . . . . . . . . . . . . . 13
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION
TORQUE
Rear Bumper Reinforcement
Attaching Nut
28 N·m (21 ft. lbs.)
Front Suspension Crossmember
Attaching Bolt Front
109 N·m (80 ft. lbs.)
Attaching Bolt Rear
102 N·m (75 ft. lbs.)
Radiator Support Crossmember
Attaching Bolts
115 N·m (85 ft. lbs.)
FRONT FASCIA
REMOVAL
REMOVAL - JR-41
It is not necessary to remove the headlamp assem-
blies to remove the front bumper fascia.
(1) Release hood latch and open hood.
(2) Remove fasteners attaching fascia to front
splash shields (Fig. 1).
(3) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE), for proper hoist-
ing and jacking procedures.
(4) Remove inner wheelhouse front wheel house
splash shield as necessary to access nut attaching
fascia wings to fender.
(5) Remove fasteners attaching top of fascia to
upper crosmember.
(6) Remove fasteners attaching bottom of fascia to
radiator closure panel and to brake ducts.
(7) Remove screws attaching fascia to front fend-
ers.
(8) Slide fascia forward to disengage hooks attach-
ing fascia to bottom of fender.
(9) Remove fascia from vehicle.
(10) Disengage fog lamp wire connector from body
harness, if equipped.
JR
FRAME & BUMPERS
13 - 1
REMOVAL - JR-27
It is not necessary to remove the headlamp assem-
blies to remove the front bumper fascia.
(1) Release hood latch and open hood.
(2) Remove fasteners attaching top of grille to
headlamp adapter assembly (Fig. 2).
(3) Hoist and support vehicle on safety stands.
(Refer to LUBRICATION & MAINTENANCE/HOIST-
ING - STANDARD PROCEDURE), for proper hoist-
ing and jacking procedures.
(4) Remove inner wheelhouse front wheel house
splash shield as necessary to access nut attaching
fascia wings to fender.
(5) Remove fasteners attaching bottom of fascia to
radiator closure panel and to brake ducts.
(6) Remove screws attaching fascia to front fend-
ers.
(7) Slide fascia forward and separate fascia from
vehicle.
(8) Disengage fog lamp wire connectors from back
of fog lamps, if so equipped.
INSTALLATION
INSTALLATION - JR-41
(1) Ensure that energy management foam is prop-
erly installed in front fascia.
(2) Engage fog lamp wire connector to body wire
harness, if equipped.
(3) Place fascia on position on vehicle (Fig. 1).
(4) Install fasteners attaching fascia to front fend-
ers.
(5) Install fasteners attaching bottom of fascia to
radiator closure panel and brake ducts.
(6) Install fasteners attaching top of fascia to
upper crossmember.
(7) Install front wheelhouse splash shields.
INSTALLATION - JR-27
(1) Ensure that energy management foam is prop-
erly installed in front fascia (Fig. 3).
(2) Engage fog lamp wire connectors to back of fog
lamps, if so equipped.
(3) Position fascia on vehicle and slide rearward,
being careful to ensure that the grille slides under
hood latch (Fig. 2).
(4) Install fasteners attaching bottom of fascia to
radiator closure panel and brake ducts.
(5) Install fasteners attaching top of fascia to
upper crossmember.
(6) Install front wheelhouse splash shields.
Fig. 1 FRONT FASCIA JR-41
1 - PUSH PIN (FASCIA TO UPPER CROSMEMBER)
2 - SCREW AND WASHER (FASCIA TO FENDER)
3 - SCREW ( FASCIA TO SPLASH SHIELD)
4 - PUSH PIN (FASCIA TO LOWER CROSSMEMBER AND BRAKE
DUCTS)
5 - FRONT FASCIA
13 - 2
FRAME & BUMPERS
JR
FRONT FASCIA (Continued)
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