Dodge Caliber. Manual — part 1121

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

UNDER FLOOR CATALYTIC CONVERTER

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
OPERATING TIME.

1. Raise vehicle on hoist and apply penetrating oil to

band clamp fastener of component being removed.

NOTE: Do not use petroleum-based lubricants
when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part.
A suitable substitute is a mixture of liquid dish
soap and water.

2. Remove I-Pipe/Muffler assembly (Refer to 11 - EXHAUST SYSTEM/MUFFLER - REMOVAL).

3. Disconnect oxygen sensor electrical connectors.

NOTE: If spherical gasket is to be reused, mark orientation.

4. Remove flange bolts (3), springs and spherical gasket.

5.

Remove under floor catalytic converter (3) from combination manifold/catalytic converter assembly (1).

6. Clean ends of pipes to assure mating of all parts. Discard broken or worn isolators, rusted or overused clamps,

supports, and attaching parts.

NOTE: When replacement is required on any component of the exhaust system, you must use original
equipment parts (or their equivalent).

PM

EXHAUST SYSTEM

11 - 9

CATALYTIC CONVERTER - FWD

WARNING: The normal operating temperature 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 converter. The
temperature of the converter rises to a high level
after a short period of engine operation time.

NOTE: Before replacing a catalytic converter,
determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or igni-
tion problems. Refer to the appropriate service
diagnostic information for repair procedures.

1. Loosen intermediate pipe-to catalytic converter

clamp.

NOTE: Do not use petroleum-based lubricants
when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and
water.

2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from vehicle.

3. Remove I-Pipe/Muffler assembly insolators as necessary to slide I-Pipe/Muffler assembly out of catalytic con-

verter.

4.

Remove and discard flange gasket.

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or
equivalent) must be used.

REMOVAL - MANIVERTER

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

CON-

VERTER RISES TO A HIGH LEVEL AFTER A
SHORT PERIOD OF ENGINE OPERATION TIME.

NOTE: Before replacing a catalytic converter,
determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or igni-
tion problems. Refer to the appropriate service
diagnostic information for repair procedures.

1. Remove under floor catalytic converter (Refer to 11

- EXHAUST SYSTEM/CATALYTIC CONVERTER -
REMOVAL).

NOTE: When replacement is required on any component of the exhaust system, original equipment parts (or
equivalent) must be used.

11 - 10

EXHAUST SYSTEM

PM

2. Lower vehicle.

3. Remove secondary thermostat (Refer to 7 - COOLING/ENGINE/ENGINE COOLANT THERMOSTAT -

REMOVAL).

4. Remove maniverter mounting bolts.

5. Remove maniverter and gasket from the engine compartment.

INSPECTION

WARNING: The normal operating temperature 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 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.

INSTALLATION

UNDER FLOOR CATALYTIC CONVERTER

When assembling exhaust system do not tighten
clamps until components are aligned and clearances
are checked.

1. Install under floor catalytic converter and the isola-

tor supports to the underbody.

2. Position spherical gasket (2) with white side facing

rear of vehicle, install springs, and bolts (3).
Tighten bolts to 33 N·m (24 ft. lbs.).

3. Install I-Pipe/muffler assembly (Refer to 11 -

EXHAUST SYSTEM/MUFFLER - INSTALLATION)

4. Working from the front of system; align each com-

ponent to maintain position and proper clearance
with underbody parts.

5. Tighten band clamps to 55 N·m (40 ft. lbs.).

CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bot-
tomed out against the center hourglass shaped
center block. Once this occurs, the clamp band
has been stretched and has lost its clamping force
and must be replaced.

NOTE: Maintain proper clamp orientation when
replacing with new clamp.

PM

EXHAUST SYSTEM

11 - 11

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 adjustments, if needed.

CATALYTIC CONVERTER - FWD

1. Position

catalytic

converter

into

I-Pipe/muffler

assembly.

2. Using

new

gasket

position

catalytic

converter

against exhaust manifold.

3. Install flange bolts. Tighten to 29 N·m (21 ft. lbs.).

4. Working from the front of system; align each com-

ponent to maintain position and proper clearance
with underbody parts.

5. Tighten band clamps to 55 N·m (40 ft. lbs.).

CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bot-
tomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
clamping force and must be replaced.

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 adjustments, if needed.

INSTALLATION - MANIVERTER

NOTE: When assembling exhaust system do not
tighten clamps until all components are aligned
and clearances are checked.

1. Position maniverter (1) in vehicle. Use a new

flange gasket.

2. Using new gasket, install maniverter (1) and

mounting bolts. Tighten bolts to 28 N·m (250 in.
lbs.).

3. Install secondary thermostat (Refer to 7 - COOL-

ING/ENGINE/ENGINE COOLANT THERMOSTAT -
INSTALLATION).

4. Install under floor catalytic converter (Refer to 11 -

EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSTALLATION).

5. Working from the front of system; align each com-

ponent to maintain position and proper clearance
with underbody parts.

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 adjustments, if needed.

11 - 12

EXHAUST SYSTEM

PM