Chrysler Stratus Convertible. Manual — part 6
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are equipped with a heat shield crimped on the top of
the 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.
EXHAUST FLEX-JOINT COUPLING
DESCRIPTION
A exhaust flex-joint coupling (Fig. 3) is used to
secure the catalytic converter to the engine manifold.
The exhaust flex-joint is welded to the catalytic
converter.
OPERATION
This joint actually moves back and forth as the
engine moves, preventing breakage that could occur
from the back-and-forth motion of a transverse
mounted engine.
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.
DIAGNOSIS AND TESTING
EXHAUST SYSTEM
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. EGR Valve to manifold gasket
leakage.
3. Tighten fasteners or replace gasket.
4. EGR Valve to EGR tube gasket
leakage.
4. Tighten fasteners or replace gasket.
5. EGR tube to manifold tube leakage.
5. Tighten tube nut.
6. Exhaust flex-joint to manifold leak.
6. Tighten joint fasteners and/or replace
gasket.
7. Exhaust flex-joint.
7. Replace catalytic converter assembly.
8. Pipe and shell noise from front
exhaust pipe.
8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST
NOISE
1. Leak at exhaust pipe joints.
1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler assembly
or exhaust pipe.
2. Replace muffler resonator tailpipe
assembly or exhaust pipe with catalytic
converter assembly.
Fig. 3 Flex-Joint Coupling—2.0L
1 – BELLOWS
2 – COVER
3 – FLANGE
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EXHAUST SYSTEM
11 - 3
DESCRIPTION AND OPERATION (Continued)
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CONDITION
POSSIBLE CAUSES
CORRECTION
3. Burned or rusted out resonator.
3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system.
4. Remove restriction if possible, or
replace component as necessary.
5. Converter material in muffler.
5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper operation.
REMOVAL AND INSTALLATION
EXHAUST SYSTEM
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 clamp nuts of component being removed (Fig. 4).
(2) Loosen clamp at muffler to resonator/pipe
assembly (Fig. 4).
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.
(3) Remove support isolators from muffler sup-
ports.
(4) Remove ground strap from muffler (Fig. 7).
(5) Remove muffler assembly from resonator pipe.
(6) Remove clamp and supports at the resonator
pipe to catalytic converter slip joint (Fig. 4). Separate
at slip joint and remove the resonator assembly.
Fig. 4 Exhaust System Components
1 – RESONATOR AND PIPE ASSEMBLY
2 – CLAMP
3 – MUFFLER AND PIPE ASSEMBLY
4 – CLAMP
5 – CATALYTIC CONVERTOR AND PIPE ASSEMBLY
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EXHAUST SYSTEM
JX
DIAGNOSIS AND TESTING (Continued)
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(7) Disconnect downstream heated oxygen sensor
from the catalytic converter pipe (Fig. 6).
(8) Remove catalytic converter to exhaust manifold
attaching fasteners (Fig. 5). Remove catalytic con-
verter from vehicle.
(9) Clean ends of pipes and/or muffler to assure
mating of all parts. Discard broken or worn insula-
tors, rusted clamps, supports and attaching parts.
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
When assembling exhaust system do not tighten
clamps until components are aligned and supports
have equal load on them (Fig. 7).
(1) Assemble catalytic convertor to exhaust mani-
fold connection (Fig. 5).
(2) Assemble resonator pipe to catalytic convertor.
Attach isolators to the supports on the underbody
(Fig. 7).
(3) Install the muffler to resonator pipe. Attach
isolators to the supports on the underbody (Fig. 7).
NOTE: Always work from the front to rear of
exhaust
system
when
aligning
and
tightening
exhaust system components.
(4) Align and tighten the catalytic convertor to
exhaust manifold fasteners (Fig. 5). Tighten fasteners
to 28 N·m (250 in. lbs.).
(5) Align each component to maintain position and
proper clearance with underbody parts. Also, all sup-
ports should have equal load on them. Tighten
clamps to 54 N·m (40 ft. lbs.) (Fig. 8).
(6) Connect ground strap.
Fig. 5 Flex-Joint Connections
1 – OXYGEN SENSOR
2 – NUT
3 – GASKET
4 – OXYGEN SENSORS
5 – NUT
6 – GASKET
Fig. 6 Downstream Heated Oxygen Sensor
1 – DOWNSTREAM HEATED OXYGEN SENSOR
2 – RUBBER GROMMET
3 – CATALYTIC CONVERTER
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EXHAUST SYSTEM
11 - 5
REMOVAL AND INSTALLATION (Continued)
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(7) Connect the downstream heated oxygen sensor
(Fig. 6).
CLEANING AND INSPECTION
EXHAUST SYSTEM
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
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, 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.
Fig. 7 Exhaust System Support Isolators—Typical
1 – GROUND STRAP
2 – RESONATOR SUPPORT ISOLATORS
3 – MUFFLER/FRONT PIPE SUPPORT ISOLATOR
4 – REAR MUFFLER SUPPORT ISOLATORS
Fig. 8 Band Clamp
1 – CLAMP SIZE
2 – TORQUE SPECIFICATION
11 - 6
EXHAUST SYSTEM
JX
REMOVAL AND INSTALLATION (Continued)
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