Chrysler PT Cruiser 2001 Service Manual Supplement page 1063

11 - 6 EXHAUST SYSTEM
REMOVAL AND INSTALLATION (Continued)
(3) Connect the exhaust system ground strap.
Fig. 8 Band Clamp
1 – CLAMP SIZE
2 – TORQUE SPECIFICATION
INTERMEDIATE PIPE
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 OPERATING TIME.
(1) Raise vehicle on hoist and apply penetrating oil
to band clamp fastener of component being removed.
NOTE: Do not use petroleum-based lubricants
when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part.
A suitable substitute is a mixture of liquid dish
soap and water.
(2) Remove muffler. Refer to procedure in this sec-
tion.
(3) Loosen band clamp and remove support isola-
tor. Remove intermediate pipe from catalytic con-
verter pipe (Fig. 9).
(4) Clean ends of pipes and muffler to assure mat-
ing of all parts. Discard broken or worn isolators,
rusted or overused clamps, supports, and attaching
parts.
NOTE: When replacement is required on any com-
ponent of the exhaust system, you must use origi-
nal equipment parts (or their equivalent).
INSTALLATION
When assembling exhaust system do not tighten
clamps until components are aligned and clearances
are checked.
(1) Install intermediate pipe and the isolator sup-
ports to the underbody (Fig. 9).
(2) Install muffler. Refer to procedure in this sec-
tion.
(3) Working from the front of system; align each
component to maintain position and proper clearance
with underbody parts. Refer to Specifications -
Exhaust System Clearance (Fig. 18) in this section.
(4) Tighten band clamps to 47 N·m (35 ft. lbs.)
(Fig. 10).
CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.
To replace the band clamp; remove the nut and
peel back the ends of the clamp until spot weld
breaks.
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
CATALYTIC CONVERTER
REMOVAL
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.
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 the appropriate service diagnos-
tic information for repair procedures.
(1) Remove muffler and intermediate pipe. Refer to
procedures in this section.
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 11).
PT