Avenger 2008

Exhaust System

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Catalytic Converter



Removal & Installation
2.4L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


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

  1. Raise and support vehicle.
  2.  
  3. Apply penetrating oil to resonator/pipe assembly band clamp (4), and the fasteners that connect the catalytic converter to the exhaust manifold.
  4.  
  5. Remove ground strap from muffler.

    Click image to see an enlarged view

    Fig. Muffler and resonator assembly-2.4L engine

  6.  
  7. Loosen band clamp for resonator/pipe assembly (4).
    CAUTION
    Do not use any tools to remove the rubber 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.

  8.  
  9. Remove support isolators from muffler/resonator assembly supports.
  10.  
  11. Remove muffler/resonator pipe as an assembly.
  12.  
  13. Disconnect oxygen sensor connector (1).

    Click image to see an enlarged view

    Fig. Disconnect oxygen sensor connector (1)

  14.  
  15. Remove flange nuts at exhaust manifold.
  16.  
  17. Remove catalytic converter from vehicle (3).
  18.  
  19. Remove and discard gasket.
  20.  

To install:


NOTE
Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

  1. Clean manifold to converter sealing surfaces.
  2.  
  3. Position new gasket on exhaust manifold.
    NOTE
    If catalytic converter is being replaced, transfer downstream oxygen sensor to new converter.

  4.  
  5. Loosely attach catalytic converter to exhaust manifold.
  6.  
  7. Loosely install resonator/pipe and muffler/pipe assembly to catalytic converter outlet pipe.
  8.  
  9. Install support isolators to muffler supports.
  10.  
  11. Align exhaust system to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners attaching catalytic converter to exhaust manifold to 21 ft. lbs. (28 Nm).
  12.  
  13. Tighten resonator/pipe assembly band clamp to 40 ft. lbs. (54 Nm).
  14.  
  15. Connect ground strap to muffler.
  16.  
  17. Lower vehicle.
  18.  
  19. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
  20.  
  21. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
  22.  

2.7L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

The 2.7L engine uses maniverter assemblies that are incorporated into the exhaust manifolds. To remove the maniverter assemblies, remove the exhaust manifolds.

The exhaust system on the 2.7L engine model consists of front and rear bank catalytic converters (maniverters), cross-under pipe, connector pipe, resonator/pipe assembly, muffler/pipe assembly, band clamps, and support isolators. The upstream oxygen sensors are located in the front and rear exhaust manifolds. The downstream oxygen sensors are located in the cross-under pipe.

Click image to see an enlarged view

Fig. Exhaust system-2.7L engine

3.5L Engine

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009


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

  1. Raise vehicle on hoist and apply penetrating oil to resonator/pipe assembly band clamp (4), and the fasteners that connect the catalytic converter to the exhaust manifold.
  2.  
  3. Remove ground strap from muffler.

    Click image to see an enlarged view

    Fig. Muffler and resonator assembly-3.5L engine

  4.  
  5. Loosen band clamp for resonator/pipe assembly (4).
    CAUTION
    Do not use any tools to remove the rubber 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.

  6.  
  7. Remove support isolators (1) from muffler/resonator assembly supports.

    Click image to see an enlarged view

    Fig. Remove support isolators (1) from muffler/resonator assembly supports

  8.  
  9. Remove muffler/resonator pipe (2) as an assembly.
  10.  
  11. Remove flange nuts (1) at cross-under pipe (4).
  12.  
  13. Remove catalytic converter from vehicle (1).
  14.  
  15. Remove and discard gasket (3).
  16.  

To install:


NOTE
Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

  1. Clean cross-under to catalytic converter sealing surfaces.
  2.  
  3. Position new gasket on cross-under pipe.
  4.  
  5. Loosely attach catalytic converter to cross-under pipe.
  6.  
  7. Loosely install muffler/resonator assembly to catalytic converter.
  8.  
  9. Install support isolators to muffler supports.
  10.  
  11. Align exhaust system to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners attaching catalytic converter to exhaust manifold to 21 ft. lbs. (28 Nm).
  12.  
  13. Tighten resonator/pipe assembly band clamp to 40 ft. lbs. (54 Nm).
  14.  
  15. Connect ground strap to muffler.
  16.  
  17. Lower vehicle.
  18.  
  19. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
  20.  
  21. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
  22.  

 
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