Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual - part 536

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 both oxygen
sensors 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, deter-
mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures.

INSTALLATION

(1) Clean manifold to converter sealing surfaces.
(2) Position new gasket on converter inlet flange

(Fig. 5).

(3) Ensure exhaust manifold heat shield is in posi-

tion, and loosely install converter with lower attach-
ing bolt to exhaust manifold.

(4) Lower vehicle.
(5) Install 3 nuts attaching converter to manifold.

Torque nuts to 28 N·m (250 in. lbs.).

(6) Reconnect upstream oxygen sensor.
(7) Raise vehicle.
(8) Torque remaining attaching bolt to 28 N·m

(250 in. lbs.).

(9) Install

cross-under

pipe

(Refer

EXHAUST

SYSTEM/CROSS-UNDER

PIPE

INSTALLATION).

(10) Lower vehicle.
(11) Connect negative battery cable.
(12) Start the engine and inspect for exhaust

leaks. Repair exhaust leaks as necessary.

(13) Check the exhaust system for contact with the

body panels. Make the necessary ajustments, if
needed.

CATALYTIC CONVERTER -
REAR - 2.7L

REMOVAL

(1) Disconnect negative battery cable.
(2) Raise vehicle on hoist.
(3) Remove entire exhaust system from vehicle

(Refer to 11 - EXHAUST SYSTEM - REMOVAL)

(4) Remove exhaust cross-under pipe (Refer to 11 -

EXHAUST

SYSTEM/CROSS-UNDER

PIPE

REMOVAL).

(5) Disconnect upstream oxgen sensor.
(6) Remove nuts attaching converter to exhaust

manifold (Fig. 6).

(7) Remove exhaust manifold heat shield.
(8) Remove catalytic converter.
(9) Remove and discard gasket.

INSPECTION

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 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

EXHAUST SYSTEM

11 - 9

CATALYTIC CONVERTER - FRONT - 2.7L (Continued)

INSTALLATION

(1) Clean manifold to converter sealing surfaces.
(2) Position new gasket on converter inlet flange

(Fig. 6).

(3) Install converter to exhaust manifold.
(4) Install exhaust manifold heat shield into posi-

tion.

(5) Install nuts attaching converter to manifold.

Torque nuts to 28 N·m (250 in. lbs.).

(6) Connect upstream oxygen sensor.
(7) Install

cross-under

pipe(Refer

EXHAUST SYSTEM/CROSS-OVER PIPE - INSTAL-
LATION).

(8) Install exhaust system on vehicle (Refer to 11 -

EXHAUST SYSTEM - INSTALLATION).

(9) Lower vehicle.
(10) Connect negative battery cable.
(11) Start the engine and inspect for exhaust

leaks. Repair exhaust leaks as necessary.

(12) Check the exhaust system for contact with the

body panels. Make the necessary ajustments, if
needed.

Fig. 6 CATALYTIC CONVERTER - REAR 2.7L

1 - NUT
2 - HEAT SHIELD
3 - CATALYTIC CONVERTER - REAR

4 - STUD
5 - GASKET

11 - 10

EXHAUST SYSTEM

CATALYTIC CONVERTER - REAR - 2.7L (Continued)

CROSS-UNDER PIPE - 2.7L

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.
(2) Disconnect downstream oxygen sensor connec-

tors.

(3) Remove oil pan to transmission structural col-

lar. (Refer to 9 - ENGINE/ENGINE BLOCK/STRUC-
TURAL COVER - REMOVAL)

(4) Disconnect exhaust system pipe from cross-un-

der pipe.

(5) Remove fasteners attaching cross-under pipe to

catalytic converters (Fig. 7).

(6) Remove cross-under pipe (Fig. 7).

INSTALLATION

(1) Install new gasket to lower part of rear cata-

lytic converter. If installing new cross-under pipe,
transfer oxygen sensors to new pipe (Fig. 7).

(2) Loosely install cross-under pipe to catalytic

converters (Fig. 7). Snug nuts up equally using hand
pressure.

(3) Tighten 2 nuts for cross-under pipe to rear cat-

alytic converter to 28 N·m (250 in. lbs.) (Fig. 7).

(4) Tighten 2 nuts for cross-under pipe to front cat-

alytic converter to 28 N·m (250 in. lbs.) (Fig. 7).

(5) Connect exhaust system pipe to cross-under

pipe. Tighten attaching fasteners to 28 N·m (250 in.
lbs.)

(6) Install oil pan to transmission structural collar-

.(Refer to 9 - ENGINE/ENGINE BLOCK/STRUC-
TURAL COVER - INSTALLATION)

Fig. 7 CROSS-UNDER PIPE

1 - EXHAUST MANIFOLD - REAR
2 - CATALYTIC CONVERTER ATTACHING STUD
3 - NUTS - PIPE-TO-REAR CONVERTER
4 - CROSS-UNDER PIPE

5 - BOLT - PIPE-TO-FRONT CONVERTER
6 - NUT - PIPE-TO-FRONT CONVERTER
7 - EXHAUST MANIFOLD - FRONT
8 - GASKET - PIPE-TO-CONVERTER

EXHAUST SYSTEM

11 - 11

(7) Reconnect downstream oxygen sensor connec-

tors.

(8) Lower vehicle.
(9) Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.

(10) Check the exhaust system for contact with the

body panels. Make the necessary ajustments, if
needed.

EXHAUST PIPE - CROSS-
UNDER PIPE TO RESONATOR
PIPE - 2.7L

REMOVAL

NOTE: In the following procedure it is not neces-
sary to separate the muffler/pipe assembly from the
resonator/pipe

assembly.

They

can

both

removed as an assembly.

(1) Raise vehicle on hoist and apply penetrating oil

to resonator/pipe assembly band clamp, and the fas-
teners that connect the exhaust system to the cross-
under pipe (Fig. 1).

(2) Remove ground strap from muffler.
(3) Loosen band clamp for resonator/pipe assembly.

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.

(4) Remove support isolators from muffler sup-

ports.

(5) Remove resonator/pipe and muffler/pipe as an

assembly.

(6) Remove fasteners that attach exhaust pipe to

cross-under pipe.

(7) Remove exhaust pipe.

INSTALLATION

NOTE: Always work from the front to rear of
exhaust

system

when

aligning

and

tightening

exhaust system components.

(1) Loosely attach exhaust pipe to cross-under

pipe.

(2) Loosely install resonator/pipe and muffler/pipe

assembly to exhaust pipe.

(3) Install support isolators to muffler supports.
(4) Align exhaust pipe and resonator/muffler pipe

assembly to maintain position and proper clearance
with underbody parts. All support isolators should
have equal load on them. Tighten fasteners attaching
exhaust pipe to cross-under pipe to 28 N·m (250 in.
lbs.).

(5) Tighten resonator/pipe assembly band clamp to

54 N·m (40 ft. lbs.).

(6) Connect ground strap to muffler.
(7) Lower vehicle.
(8) Start the engine and inspect for exhaust leaks.

Repair exhaust leaks as necessary.

(9) Check the exhaust system for contact with the

body panels. Make the necessary ajustments, if
needed.

MUFFLER/PIPE ASSEMBLY

REMOVAL

(1) Raise vehicle on hoist and apply penetrating oil

to band clamp of component being removed (Fig. 1).

(2) Remove ground strap from muffler.
(3) Loosen band clamp for muffler/pipe assembly.

(4) Remove support isolators from muffler supports

(Fig. 2).

11 - 12

EXHAUST SYSTEM

CROSS-UNDER PIPE - 2.7L (Continued)

Content .. 534 535 536 537 ..