DESCRIPTION - US Cars
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebring2007 ENGINEExhaust System - SebringDESCRIPTIONEXHAUST SYSTEM-DESCRIPTIONFig. 1: Identifying Exhaust System ComponentsCourtesy of CHRYSLER LLC1 - FLEX JOINT2 - BAND CLAMP3 - RESONATOR/PIPE ASSEMBLY4 - MUFFLER/PIPE ASSEMBLY5 - REAR MUFFLER SUPPORTS6 - MIDPIPE SUPPORT7 - OXYGEN SENSOR8 - CATALYTIC CONVERTOR (2.0L/2.4L)9 - CONNECTOR PIPE (2.7L)The exhaust system on the 2.0L/2.4L engine models consists of a front mountedcatalytic converter, resonator/pipe assembly, muffler/pipe assembly, band clampsand support isolators. The upstream oxygen sensor is located in the exhaustmanifold. The downstream oxygen sensor is located in the catalytic converter.meSaturday, April 18, 2009 3:12:223:12:19 AMPage 1 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringFig. 2: Identifying Exhaust System SupportsCourtesy of CHRYSLER LLC1 - GROUND STRAP2 - MUFFLER/FRONT PIPE SUPPORT ISOLATOR3 - REAR MUFFLER SUPPORT ISOLATORSThe exhaust system on the 2.7L engine model consists of front and rear bankcatalytic converters, cross-under pipe, connector pipe, resonator/pipe assembly,muffler/pipe assembly, band clamps and support isolators. The upstream oxygensensors are located in the front and rear exhaust manifolds. The downstream oxygensensors are located in the cross-under pipe.Resonators, mufflers and exhaust pipes are tuned to each powertrain combination.DIAGNOSIS AND TESTINGRESTRICTION CHECKExhaust system restriction can be checked by measuring back pressure using thescan tool and PEP module pressure tester.meSaturday, April 18, 2009 3:12:19 AMPage 2 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringWARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Disconnect and remove the upstream (before catalytic converter) oxygensensor. Refer to REMOVAL .2. Install the Exhaust Back Pressure Fitting Adapter 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 tothe scan tool and PEP module. Select the available menu options on the scandisplay 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 scan. Back pressure should not exceedspecified limit. Refer to specification in EXHAUST BACK PRESSURELIMITS.NOTE:For applications with dual catalytic converters, repeattest on opposite converter using the previous steps.7. If pressure exceeds maximum limits, inspect exhaust system for restrictedcomponent. For further catalytic converter inspection procedures, seeINSPECTION. Replace component(s) as necessary.EXHAUST BACK PRESSURE LIMITSExhaust Back Pressure Limit (Max)Vehicle in Park/Neutral (no load)@2000 RPM3.45 kPa (0.5 psi)LEAK TESTINGmeSaturday, April 18, 2009 3:12:19 AMPage 3 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringWARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Raise and support vehicle.CAUTION: The air pressure must not exceed 4 psi,otherwise engine damage can occur.2. Connect Tool 8404-EC or 8404-ECT, Exhaust Cone to an adjustable airpressure regulator.3. Attach shop air to the air pressure regulator.4. Adjust the air pressure regulator to 4 psi5. Insert Tool 8404-EC or 8404-ECT, Exhaust Cone into the vehicle tail pipe.6. If the vehicle is equipped with dual exhaust, use Tool 8404-EC or 8404-ECT,Exhaust Cone with equipped attached plug. Plug one side of the dual exhaustpipe. Pressurize the other as described.7. Apply a mixture of liquid dish soap and water to the following areas:- All welded joints from 6 inches rearward of the downstream O2 sensorforward- O2 sensor seal points- O2 sensor boss welds- Flange/joint connection(s)- Exhaust manifold to cylinder head connection(s)- EGR solenoid gasket base and tube seal points (if equipped)8. Watch for the liquid/soapy water to bubble.9. Use the following definitions to help determine if system or componentrepair/replacement is necessary:Type 1 Leak is defined as a leak where very small foam like bubbles 1meSaturday, April 18, 2009 3:12:19 AMPage 4 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringmm (.039 in.) or less appear. Any Type 1 or greater leaks found in weldedjoints, O2 sensor seal points or O2 sensor boss welds must be repaired orthe component must be replaced.Type 2 Leak is defined as a leak where larger bubbles 8 mm (.031 in.) orgreater appear. Any Type 2 or greater leaks found in flange or jointconnections, exhaust manifold to cylinder head connections or EGRgasket and tube seal points must be repaired or the components must bereplaced.Leak LocationWelded jointsO2 Sensor seal pointsO2 Sensor boss weldsFlange/joint connectionsExhaust Manifold to cylinder headconnectionsEGR gasket and tube seal pointsRepair required if results at 4 psireveal bubble size:Type 1 - 1 mm (.039 in.) or greaterType 1 - 1 mm (.039 in.) or greaterType 1 - 1 mm (.039 in.) or greaterType 2 - 8 mm (.031 in.) or greaterType 2 - 8 mm (.031 in.) or greaterType 2 - 8 mm (.031 in.) or greaterIf a leak is found that matches the above definition, repair or replace the componentas necessary.Once the repair is complete, repeat the procedure to verify that all leaks have beenrepaired.EXCESSIVE EXHAUST SYSTEM NOISECONDITIONEXCESSIVEEXHAUST NOISE(UNDER HOOD)POSSIBLE CAUSESCORRECTION1. Exhaust manifold1. Replace manifold.cracked or broken.2. Manifold to cylinder 2. Tighten manifold and/orhead leak.replace gasket.3. EGR Valve to3. Tighten fasteners ormanifold gasket leakage. replace gasket.4. EGR Valve to EGR 4. Tighten fasteners ormeSaturday, April 18, 2009 3:12:19 AMPage 5 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringtube gasket leakage.5. EGR tube to manifoldtube leakage.6. Exhaust flex-joint tomanifold leak.7. Exhaust flex-joint.EXCESSIVEEXHAUST NOISE8. Pipe and shell noisefrom front exhaust pipe.1. Leak at exhaust pipejoints.2. Burned or rusted outmuffler assembly orexhaust pipe.3. Burned or rusted outresonator.4. Restriction in exhaustsystem.5. Converter material inmuffler.replace gasket.5. Tighten tube nut.6. Tighten joint fastenersand/or replace gasket.7. Replace catalyticconverter assembly.8. Characteristic of singlewall pipe.1. Tighten clamps at leakingjoints.2. Replace mufflerresonator tailpipe assemblyor exhaust pipe withcatalytic converterassembly.3. Replace mufflerresonator tailpipe assembly.4. PerformRESTRICTION CHECK.Replace component asnecessary.5. Replace muffler andconverter assemblies.Check fuel injection andignition systems for properoperation.REMOVALEXHAUST SYSTEM-REMOVALNOTE:Some service procedures require the removal of the entireexhaust system in order to gain better access to certaincomponents for removal and installation. The followingmeSaturday, April 18, 2009 3:12:19 AMPage 6 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringprocedure explains how to remove the entire exhaustsystem. Refer to specific procedures if replacing individualexhaust components.WARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Raise vehicle on hoist and apply penetrating oil to fasteners that connect theexhaust system to the exhaust manifold (2.0L/2.4L)/cross-under pipe (2.7L).2. Remove ground strap from muffler.3. Vehicles equipped with 2.0L/2.4L engines, disconnect downstream oxygensensor connector.4. Remove fasteners that attach exhaust system to exhaust manifold(2.0L/2.4L)/cross-under pipe (2.7L).CAUTION: Do not use any tools to remove the rubberisolators - remove by hand only. Soapy water orsilicone-based lubricant spray may be used toassist removal/installation of isolators. DO NOTuse a petroleum-based lubricant on the isolators,as damage to the rubber material can occur.5. Remove support isolators from muffler supports.6. Remove exhaust system from vehicle.NOTE:Band clamps are spot welded to exhaust system. If a bandclamp must be replaced, the spot weld must be ground offthe exhaust pipe.NOTE:When replacement is required on any component of themeSaturday, April 18, 2009 3:12:19 AMPage 7 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringexhaust system, it is most important that originalequipment parts (or their equivalent) be used for thefollowing reasons:To insure proper alignment with other parts in the system.Provide acceptable exhaust noise levels and does not change exhaust systemback pressure that could affect emissions and performance.INSPECTIONINSPECTIONInspect the exhaust pipes, catalytic converters, muffler and resonators for crackedjoints, broken welds and corrosion damage that would result in a leaking exhaustsystem. Inspect the clamps, support brackets and insulators for cracks and corrosiondamage.INSTALLATIONEXHAUST SYSTEM-INSTALLATIONNOTE:Always work from the front to rear of exhaust system whenaligning and tightening exhaust system components.1. Loosely install fasteners that attach exhaust system to exhaust manifold(2.0L/2.4L)/cross-under pipe (2.7L).2. Install support isolators to exhaust system supports.3. Align exhaust system to maintain position and proper clearance withunderbody parts. All support isolators should have equal load on them. Tightenfasteners that attach exhaust system to exhaust manifold (2.0L/2.4L)/crossunder pipe (2.7L) to 28 N.m (250 in. lbs.).4. Vehicles equipped with 2.0L/2.4L engines, reconnect the downstream oxygensensor connector.5. Connect ground strap to muffler.6. Lower vehicle.7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks asmeSaturday, April 18, 2009 3:12:19 AMPage 8 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringnecessary.8. Check the exhaust system for contact with the body panels. Make the necessaryadjustments, if needed.ADJUSTMENTSADJUSTMENTSA misaligned exhaust system is usually indicated by a vibration, rattling noise orbinding of exhaust system components. These noises are sometimes hard todistinguish from other chassis noises. Inspect exhaust system for broken or looseclamps, heat shields, isolators, and brackets. Replace or tighten as necessary. It isimportant that exhaust system clearances 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 alignment and clearances are achieved.SPECIFICATIONSSPECIFICATION-TORQUETORQUE SPECIFICATIONSDESCRIPTIONFastener, Band ClampsFasteners, Body Heat ShieldFasteners, Catalytic Converter to ExhaustManifold FlangeFasteners, Cross-Under Pipe (2.0L/2.4L)Fasteners, Cross-Under Pipe (2.7L)N.m545Ft. Lbs.40-In. Lbs.4028-2502828-250250SPECIAL TOOLSSPECIAL TOOLSmeSaturday, April 18, 2009 3:12:19 AMPage 9 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringFig. 3: Back Pressure Test Adapter - CH8519Courtesy of CHRYSLER LLCFig. 4: Exhaust Cone Tool - 8404-ECTCourtesy of CHRYSLER LLCmeSaturday, April 18, 2009 3:12:19 AMPage 10 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringFig. 5: Pressure Transducer CH7063Courtesy of CHRYSLER G: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.CAUTION: DO NOT remove spark plug wires from plugs or byany other means short out cylinders. Failure of thecatalytic converter can occur due to a temperaturemeSaturday, April 18, 2009 3:12:19 AMPage 11 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringincrease caused by unburned fuel passing throughthe converter.The stainless steel catalytic converter body is designed to last the life of the vehicle.Excessive heat can result in bulging or other distortion, but excessive heat will notbe the fault of the converter. If unburned fuel enters the converter, overheating mayoccur. If a converter is heat-damaged, correct the cause of the damage at the sametime the converter is replaced. Also, inspect all other components of the exhaustsystem for heat damage.Unleaded gasoline must be used to avoid contaminating the catalyst core.REMOVALCATALYTIC CONVERTER-REMOVAL-2.0L/2.4LFig. 6: Identifying Muffler & Resonator AssemblyCourtesy of CHRYSLER LLC1 - ISOLATOR2 - MUFFLER/RESONATOR ASSEMBLY3 - CATALYTIC CONVERTER4 - BAND CLAMPWARNING: The normal operating temperature of the exhaustmeSaturday, April 18, 2009 3:12:19 AMPage 12 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Raise and support vehicle.2. Apply penetrating oil to resonator/pipe assembly band clamp (4), and thefasteners that connect the catalytic converter to the exhaust manifold.3. Remove ground strap from muffler.4. Loosen band clamp for resonator/pipe assembly (4).CAUTION: Do not use any tools to remove the rubberisolators, remove by hand only. Soapy water orsilicone based lubricant spray may be used toassist removal/installation of isolators. DO NOTuse a petroleum based lubricant on the isolators,as damage to the rubber material can occur.5. Remove support isolators from muffler/resonator assembly supports.6. Remove muffler/resonator pipe as an assembly.Fig. 7: Identifying Catalytic Converter - 2.0/2.4LmeSaturday, April 18, 2009 3:12:19 AMPage 13 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringCourtesy of CHRYSLER LLC1 - OXYGEN SENSOR ELECTRICAL CONNECTOR2 - FLANGE NUTS3 - CATALYTIC CONVERTER - 2.0/2.4L7.8.9.10.Disconnect oxygen sensor connector (1).Remove flange nuts at exhaust manifold.Remove catalytic converter from vehicle (3).Remove and discard gasket.REMOVAL-FRONT-2.7LFig. 8: View Of Front Catalytic Converter - 2.7LCourtesy of CHRYSLER LLCmeSaturday, April 18, 2009 3:12:19 AMPage 14 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebring1 - STUD2 - CATALYTIC CONVERTER3 - GASKET4 - HEAT SHIELD5 - NUTWARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never attempt toservice any part of the exhaust system until it iscooled. Special care should be taken when workingnear the catalytic converter. The temperature of theconverter rises to a high level after a short period ofengine operation time.1. Disconnect negative battery cable.2. Disconnect upstream oxygen sensor connector.3. Remove 3 converter attaching nuts that are visible from the enginecompartment.4. Raise vehicle on hoist.5. Remove exhaust cross-under pipe. See REMOVAL.6. Remove remaining bolt attaching converter to exhaust manifold.7. Remove catalytic converter.8. Remove and discard gasket.REMOVAL-3.5LmeSaturday, April 18, 2009 3:12:19 AMPage 15 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringFig. 9: View Of Muffler/Resonator Assembly - 3.5LCourtesy of CHRYSLER LLC1 - ISOLATOR2 - MUFFLER/RESONATOR ASSEMBLY - 3.5L3 - CATALYTIC CONVERTER4 - BAND CLAMPWARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Raise vehicle on hoist and apply penetrating oil to resonator/pipe assemblyband clamp (4), and the fasteners that connect the catalytic converter to theexhaust manifold.2. Remove ground strap from muffler.3. Loosen band clamp for resonator/pipe assembly (4).CAUTION: Do not use any tools to remove the rubbermeSaturday, April 18, 2009 3:12:19 AMPage 16 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringisolators, remove by hand only. Soapy water orsilicone based lubricant spray may be used toassist removal/installation of isolators. DO NOTuse a petroleum based lubricant on the isolators,as damage to the rubber material can occur.Fig. 10: Identifying Catalytic Converter - 3.5LCourtesy of CHRYSLER LLC1 - NUT2 - CATALYTIC CONVERTER3 - GASKET4 - CROSS-UNDER PIPE4.5.6.7.8.Remove support isolators (1) from muffler/resonator assembly supports.Remove muffler/resonator pipe (2) as an assembly.Remove flange nuts (1) at cross-under pipe (4).Remove catalytic converter from vehicle (1).Remove and discard gasket (3).REMOVAL-2.0L DIESELmeSaturday, April 18, 2009 3:12:19 AMPage 17 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - SebringFig. 11: Identifying Muffler & Resonator AssemblyCourtesy of CHRYSLER LLC1 - ISOLATOR2 - MUFFLER/RESONATOR ASSEMBLY3 - CATALYTIC CONVERTER4 - BAND CLAMPWARNING: The normal operating temperature of the exhaustsystem is very high. Therefore, never work aroundor attempt to service any part of the exhaust systemuntil it is cooled. Special care should be taken whenworking near the catalytic converter. Thetemperature of the converter rises to a high levelafter a short period of engine operation time.1. Raise and support vehicle. on hoist2. Apply penetrating oil to muffler and resonator assembly band clamp (4), andthe fasteners that connect the catalytic converter to the exhaust manifold.3. Remove ground strap from muffler.4. Loosen band clamp for resonator/pipe assembly (4).CAUTION: Do not use any tools to remove the rubbermeSaturday, April 18, 2009 3:12:19 AMPage 18 2005 Mitchell Repair Information Company, LLC.
2007 Chrysler Sebring2007 ENGINE Exhaust System - Sebringisolators, remove by hand only. Soapy water orsilicone based lubricant spray may be used toassist removal/installation of isolators. DO NOTuse a petroleum based lubricant on the isolators,as damage to the rubber material can occur.5. Remove support isolators from muffler/resonator assembly supports.6. Remove muffler and resonator assembly.Fig. 12: View Of Catalytic Converter - 2.0L DieselCourtesy of CHRYSLER LLC1 - TURBOCHARGER CLAMP2
Following the PEP module instruction manual, connect all required cables to . 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 . 2007 Chrysler Sebring 2007 ENGINE Exhaust System - Sebring me
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