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2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. Fig 2 Identifying Exhaust System Supports,Courtesy of CHRYSLER LLC. 1 GROUND STRAP,2 MUFFLER FRONT PIPE SUPPORT ISOLATOR. 3 REAR MUFFLER SUPPORT ISOLATORS, The exhaust system on the 2 7L engine model consists of front and rear bank. catalytic converters 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, Resonators mufflers and exhaust pipes are tuned to each powertrain combination.
DIAGNOSIS AND TESTING,RESTRICTION CHECK, Exhaust system restriction can be checked by measuring back pressure using the. scan tool and PEP module pressure tester, Saturday April 18 2009 3 12 19 AM Page 2 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. 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 Disconnect and remove the upstream before catalytic converter oxygen. sensor 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 to. the scan tool and PEP module Select the available menu options on the scan. display 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 exceed. specified limit Refer to specification in EXHAUST BACK PRESSURE. NOTE For applications with dual catalytic converters repeat. test on opposite converter using the previous steps. 7 If pressure exceeds maximum limits inspect exhaust system for restricted. component For further catalytic converter inspection procedures see. INSPECTION Replace component s as necessary,EXHAUST BACK PRESSURE LIMITS. Exhaust Back Pressure Limit Max,Vehicle in Park Neutral no load.
3 45 kPa 0 5 psi,LEAK TESTING, Saturday April 18 2009 3 12 19 AM Page 3 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. 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.
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 air. pressure regulator,3 Attach shop air to the air pressure regulator. 4 Adjust the air pressure regulator to 4 psi, 5 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 exhaust. pipe 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 sensor. 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 component. repair replacement is necessary, Type 1 Leak is defined as a leak where very small foam like bubbles 1. Saturday April 18 2009 3 12 19 AM Page 4 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. mm 039 in or less appear Any Type 1 or greater leaks found in welded. joints O2 sensor seal points or O2 sensor boss welds must be repaired or. the component must be replaced, Type 2 Leak is defined as a leak where larger bubbles 8 mm 031 in or.
greater appear Any Type 2 or greater leaks found in flange or joint. connections exhaust manifold to cylinder head connections or EGR. gasket and tube seal points must be repaired or the components must be. Repair required if results at 4 psi,Leak Location,reveal bubble size. Welded joints Type 1 1 mm 039 in or greater, O2 Sensor seal points Type 1 1 mm 039 in or greater. O2 Sensor boss welds Type 1 1 mm 039 in or greater. Flange joint connections Type 2 8 mm 031 in or greater. Exhaust Manifold to cylinder head,Type 2 8 mm 031 in or greater. connections, EGR gasket and tube seal points Type 2 8 mm 031 in or greater. If a leak is found that matches the above definition repair or replace the component. as necessary, Once the repair is complete repeat the procedure to verify that all leaks have been.
EXCESSIVE EXHAUST SYSTEM NOISE,CONDITION POSSIBLE CAUSES CORRECTION. EXCESSIVE 1 Exhaust manifold 1 Replace manifold,EXHAUST NOISE cracked or broken. UNDER HOOD 2 Manifold to cylinder 2 Tighten manifold and or. head leak replace gasket,3 EGR Valve to 3 Tighten fasteners or. manifold gasket leakage replace gasket,4 EGR Valve to EGR 4 Tighten fasteners or. Saturday April 18 2009 3 12 19 AM Page 5 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring.
tube gasket leakage replace gasket,5 EGR tube to manifold 5 Tighten tube nut. tube leakage,6 Exhaust flex joint to 6 Tighten joint fasteners. manifold leak and or replace gasket,7 Exhaust flex joint 7 Replace catalytic. converter assembly,8 Pipe and shell noise 8 Characteristic of single. from front exhaust pipe wall pipe, EXCESSIVE 1 Leak at exhaust pipe 1 Tighten clamps at leaking.
EXHAUST NOISE joints joints,2 Burned or rusted out 2 Replace muffler. muffler assembly or resonator tailpipe assembly,exhaust pipe or exhaust pipe with. catalytic converter,3 Burned or rusted out 3 Replace muffler. resonator resonator tailpipe assembly,4 Restriction in exhaust 4 Perform. system RESTRICTION CHECK,Replace component as,5 Converter material in 5 Replace muffler and.
muffler converter assemblies,Check fuel injection and. ignition systems for proper,EXHAUST SYSTEM REMOVAL. NOTE Some service procedures require the removal of the entire. exhaust system in order to gain better access to certain. components for removal and installation The following. Saturday April 18 2009 3 12 19 AM Page 6 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. procedure explains how to remove the entire exhaust. system Refer to specific procedures if replacing individual. exhaust components, 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 fasteners that connect the. exhaust 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 oxygen. sensor 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 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,5 Remove support isolators from muffler supports. 6 Remove exhaust system from vehicle, NOTE Band clamps are spot welded to exhaust system If a band. clamp must be replaced the spot weld must be ground off. the exhaust pipe, NOTE When replacement is required on any component of the.
Saturday April 18 2009 3 12 19 AM Page 7 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. exhaust system it is most important that original, equipment parts or their equivalent be used for the. following reasons, To insure proper alignment with other parts in the system. Provide acceptable exhaust noise levels and does not change exhaust system. back pressure that could affect emissions and performance. INSPECTION,INSPECTION, Inspect the exhaust pipes catalytic converters muffler and resonators for cracked. joints broken welds and corrosion damage that would result in a leaking exhaust. system Inspect the clamps support brackets and insulators for cracks and corrosion. INSTALLATION,EXHAUST SYSTEM INSTALLATION, NOTE Always work from the front to rear of exhaust system when.
aligning 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 with. underbody parts All support isolators should have equal load on them Tighten. fasteners that attach exhaust system to exhaust manifold 2 0L 2 4L cross. under pipe 2 7L to 28 N m 250 in lbs, 4 Vehicles equipped with 2 0L 2 4L engines reconnect the downstream oxygen. sensor connector,5 Connect ground strap to muffler. 6 Lower vehicle, 7 Start the engine and inspect for exhaust leaks Repair exhaust leaks as.
Saturday April 18 2009 3 12 19 AM Page 8 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. 8 Check the exhaust system for contact with the body panels Make the necessary. adjustments if needed,ADJUSTMENTS,ADJUSTMENTS, A misaligned exhaust system is usually indicated by a vibration rattling noise or. binding of exhaust system components These noises are sometimes hard to. distinguish from other chassis noises Inspect exhaust system for broken or loose. clamps heat shields isolators and brackets Replace or tighten as necessary It is. important 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. SPECIFICATIONS,SPECIFICATION TORQUE,TORQUE SPECIFICATIONS. DESCRIPTION N m Ft Lbs In Lbs,Fastener Band Clamps 54 40.
Fasteners Body Heat Shield 5 40,Fasteners Catalytic Converter to Exhaust. Manifold Flange,Fasteners Cross Under Pipe 2 0L 2 4L 28 250. Fasteners Cross Under Pipe 2 7L 28 250,SPECIAL TOOLS. SPECIAL TOOLS, Saturday April 18 2009 3 12 19 AM Page 9 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring.
Fig 3 Back Pressure Test Adapter CH8519,Courtesy of CHRYSLER LLC. Fig 4 Exhaust Cone Tool 8404 ECT,Courtesy of CHRYSLER LLC. Saturday April 18 2009 3 12 19 AM Page 10 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. Fig 5 Pressure Transducer CH7063,Courtesy of CHRYSLER LLC. CONVERTER CATALYTIC,DESCRIPTION,DESCRIPTION, 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, CAUTION DO NOT remove spark plug wires from plugs or by. any other means short out cylinders Failure of the. catalytic converter can occur due to a temperature. Saturday April 18 2009 3 12 19 AM Page 11 2005 Mitchell Repair Information Company LLC. 2007 Chrysler Sebring,2007 ENGINE Exhaust System Sebring. increase caused by unburned fuel passing through,the 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 not. be the fault of the converter If unburned fuel enters the converter overheating may. occur If a converter is heat damaged correct the cause of the damage at the same. time the converter is replaced Also inspect all other components of the exhaust. system for heat damage, Unleaded gasoline must be used to avoid contaminating the catalyst core. CATALYTIC CONVERTER REMOVAL 2 0L 2 4L,Fig 6 Identifying Muffler Resonator Assembly. Courtesy of CHRYSLER LLC,1 ISOLATOR,2 MUFFLER RESONATOR ASSEMBLY. DESCRIPTION N m Ft Lbs In Lbs Fastener Band Clamps 54 40 Fasteners Body Heat Shield 5 40 Fasteners Catalytic Converter to Exhaust Manifold Flange 28 250 Fasteners Cross Under Pipe 2 0L 2 4L 28 250 Fasteners Cross Under Pipe 2 7L 28 250 2007 Chrysler Sebring 2007 ENGINE Exhaust System Sebring me

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