Chrysler 300M, Dodge Interpid. Manual — part 261

two front close coupled catalytic converters. Both con-
verters attach directly to the exhaust manifold using
a V-Band clamp. The exhaust down pipes exit the
converters and connect into the front resonator. The
front resonator, intermediate pipe, and muffler are
one single module. The rear resonator and tailpipe
connect to the muffler outlet. The 300M Special has
both a left and right rear resonator. The upstream
oxygen sensors are located in each exhaust manifold.
The downstream oxygen sensors are located at the
rear of each catalytic converter.

EXHAUST SYSTEM

11 - 1

Fig. 1 Exhaust System

1 - V-BAND CLAMPS
2 - BAND CLAMPS
3 - FRONT RESONATOR
4 - INTERMEDIATE PIPE

5 - MUFFLER
6 - BAND CLAMP
7 - LEFT REAR RESONATOR/PIPE ASSEMBLY
8 - CATALYTIC CONVERTERS

Fig. 2 Exhaust System - 300M Special

1 - V-BAND CLAMPS
2 - BAND CLAMPS
3 - FRONT RESONATOR
4 - MUFFLER
5 - NUTS—28 N·m (250 in. lbs.)

6 - RIGHT REAR RESONATOR/PIPE ASSEMBLY
7 - BAND CLAMP
8 - LEFT REAR RESONATOR/PIPE ASSEMBLY
9 - CATALYTIC CONVERTERS

11 - 2

EXHAUST SYSTEM

EXHAUST SYSTEM (Continued)

DIAGNOSIS AND TESTING

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 tube 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. Exhaust to manifold leak.

5. Tighten or replace V-Band Clamp.

6. Pipe and shell noise from front
exhaust pipe.

6. 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 exhaust module, rear
resonator/tailpipe assembly or
exhaust pipe with catalytic converter
assembly.

3. Burned or rusted out
resonator(s).

3. Replace resonator assembly.

4. Restriction in exhaust system.

4. Remove restriction if possible, or
replace components as necessary.

5. Converter material in muffler or
resonators.

5. Replace muffler, resonators and
converter assemblies. Check fuel
injection and ignition systems for
proper operation.

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.

(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.

NOTE: For applications with dual catalytic convert-
ers, repeat test on opposite converter using the
previous steps.

EXHAUST SYSTEM

11 - 3

EXHAUST SYSTEM (Continued)

(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)

REMOVAL - EXHAUST SYSTEM

It is easier to service the exhaust system module

components (Fig. 1) or (Fig. 2), when system is
removed from the vehicle.

(1) Raise vehicle on hoist.
(2) Apply penetrating oil and loosen band clamps

at resonator connector.

(3) Remove

screw

attaching

exhaust

system

ground strap to left rear resonator.

(4) Separate exhaust module at front resonator

from the converter downpipes.

CAUTION: At this time, the exhaust system is held
by only isolators. Support the exhaust system
underneath the front resonator and the muffler
while the isolators are being removed. Do not use
any tools to remove the isolators, remove by hand
only. Soapy water or silicone-based spray may be
used to assist removal. Do Not use a petroleum-
based lubricant on the isolators. This will damage
the rubber material.

(5) Support exhaust system with jack stand.
(6) Remove the rubber isolators from the rear sus-

pension crossmember and support brackets on body
(Fig. 3) and (Fig. 4).

(7) Lower exhaust system and lay on the ground.

NOTE: When replacement is required on any com-
ponent of the exhaust system, it is most important
that original equipment parts be used for the follow-
ing reasons:

• To ensure 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.

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

(1) Install and loose assemble the front resonator

to the converter pipes.

(2) Place the exhaust system on two supports (one

on side of muffler, one behind the resonator). Connect
the system to the converter pipes.

(3) Install the system’s rubber isolators onto the

support brackets (Fig. 3) and (Fig. 4).

(4) Install exhaust system ground strap.
(5) Visually inspect the isolators. They should be

straight when viewing from front to back of the vehi-
cle. Working from the front of system, align each

Fig. 3 Rubber Isolator Hanger to Body Support

1 - SUPPORT BRACKET
2 - ISOLATOR
3 - RESONATOR/PIPE

11 - 4

EXHAUST SYSTEM

EXHAUST SYSTEM (Continued)

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