Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 1694
INSTALLATION - DIESEL
WARNING: The normal operating temperature 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 converter rises
to a high level after a short period of engine oper-
ation time.
1. Install the catalyst assembly.
2. Install the nuts to the down pipe (2).
3. Install mounting bolts (4) and (7).
4. Install exhaust onto the diesel particulate filter (5).
5. Connect downstream oxygen sensor connectors
(4).
6. Connect exhaust temperature sensors (3).
7. Connect differential pressure ports (2).
8. Connect negative battery cable.
INSPECTION
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THERE-
FORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPE-
CIAL
CARE
SHOULD
BE
TAKEN
WHEN
WORKING
NEAR
THE
CATALYTIC
CONVERTER.
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 sensor(s) and
insert borescope. If borescope is not available, remove converter and inspect element using a flashlight. Inspect
element for cracked or melted substrate.
NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic converter
failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic Information) for test
procedures.
11 - 10
EXHAUST SYSTEM
LX
INSTALLATION
RIGHT HAND CATALYTIC CONVERTER
1. Install catalytic converter (3) onto exhaust manifold
ball flange. Only finger tighten nuts at this time.
2. Install muffler and resonator assembly (Refer to 11
- EXHAUST SYSTEM/MUFFLER - REMOVAL).
3. Install bolts and cross brace (3). Tighten bolts to 55
N·m (40 ft. lbs.).
4. TIghten manifold ball flange nut to 12 N·m (106 in.
lbs.).
5. Check clearance between exhaust module and fuel
tank. Clearance is 14mm (.55 in.) for V8 engine
and 16mm (.62 in.) for V6 engine.
6. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
7. Adjust clearance as necessary.
8. Tighten ball flange nuts to 34 N·m (25 ft. lbs.).
9. Connect oxygen sensor (2) connectors.
10. Lower vehicle.
11. Connect negative battery cable.
12. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
LX
EXHAUST SYSTEM
11 - 11
LEFT HAND CATALYTIC CONVERTER
1. Install catalytic converter (3) onto exhaust manifold
ball flange. Only finger tighten nuts at this time.
2. Install muffler and resonator assembly (Refer to 11
-
EXHAUST SYSTEM/MUFFLER
-
INSTALLA-
TION).
3. Install bolts and cross brace. Tighten bolts to 55
N·m (40 ft. lbs.).
4. Tighten manifold ball flange nut to 12 N·m (106 in.
lbs.).
5. Check clearance between exhaust module and fuel
tank. Clearance is 14mm (.55 in.) for V8 engine
and 16mm (.62 in.) for V6 engine.
6. Check clearance at rear tunnel reinforcement.
Clearance is 15 - 20mm (.59 - .78 in.).
7. Adjust clearance as necessary.
8. Tighten ball flange nuts to 34 N·m (25 ft. lbs.).
9. Lower vehicle.
10. Connect negative battery cable.
11. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
11 - 12
EXHAUST SYSTEM
LX
HEAT SHIELDS
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 TEM-
PERATURE OF THE CONVERTER RISES TO A
HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE
OPERATION TIME.
1. Raise vehicle.
2. Remove nuts (2).
3. Remove heat shields (1).
INSTALLATION
1. Position heat shields (1).
2. Install nuts (2). Tighten nuts to 10 N·m (98 in. lbs.).
LX
EXHAUST SYSTEM
11 - 13
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