Chrysler Caravan/Voyager/Town n Country 1984-1995

Exhaust (Converter/Resonator) Pipe

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REMOVAL & INSTALLATION



  1. Raise the vehicle and properly support on jackstands.
  2.  


CAUTION
Be very careful when working on or near the catalytic converter! External temperatures can reach 1500°F (816°C) and more, causing severe burns! Removal or installation should be performed only on a cold exhaust system.

  1. Apply penetrating oil to clamp bolts, nuts and connecting points of system to be remove.
  2.  
  3. Remove the nuts and clamp assembly from exhaust pipe to muffler connecting point.
  4.  
  5. Remove the shoulder bolts, springs and nuts attaching exhaust pipe to exhaust manifold.
  6.  
  7. Remove the exhaust pipe/converter assembly from muffler.
  8.  

To install:
  1. Clean the exhaust manifold to exhaust pipe/converter assembly gasket mating surfaces and the end of muffler with a wire brush.
  2.  
  3. Install the exhaust pipe/converter assembly or resonator into muffler. Make certain the key on the converter or resonator pipe bottomed in slot of muffler.
  4.  
  5. Install a new gasket on the exhaust pipe and position exhaust pipe into exhaust manifold. Install springs, shoulder bolts and nuts. Tighten the nuts to 21 ft. lbs. (28 Nm).
  6.  
  7. Align the parts, then install a new clamp assembly at the exhaust pipe and muffler connecting point. Tighten the clamps nuts to 23 ft. lbs. (31 Nm).
  8.  

 
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