Chrysler PT Cruiser Service & Repair Manual page 1266

11 - 10 EXHAUST SYSTEM AND TURBOCHARGER
CATALYTIC CONVERTER (Continued)
and (Refer to 11 - EXHAUST SYSTEM/INTERMEDI-
ATE PIPE - REMOVAL).
(2) Disconnect downstream oxygen sensor electri-
cal connector (Fig. 8).
Fig. 8 Downstream 1/2 Oxygen Sensor - Typical
1 - DOWN STREAM O2 SENSOR
2 - UP STREAM O2 SENSOR
(3) Remove catalytic converter to exhaust manifold
attaching fasteners and remove converter from vehi-
cle (Fig. 9), (Fig. 10), (Fig. 11) or (Fig. 12).
(4) Remove and discard flange gasket.
NOTE: When replacement is required on any com-
ponent of the exhaust system, original equipment
parts (or equivalent) must be used.
INSPECTION
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.
Check catalytic converter for a flow restriction.
(Refer to 11 - EXHAUST SYSTEM - DIAGNOSIS
AND TESTING) Exhaust System Restriction Check
for procedure.
Visually inspect the catalytic converter element by
using a borescope or equivalent. Remove oxygen sen-
sor(s) and insert borescope. If borescope is not avail-
able, remove converter and inspect element using a
Fig. 9 Converter to Exhaust Manifold Connection -
1 - GASKET
2 - NUT
3 - CATALYTIC CONVERTER
4 - BOLT
5 - SUPPORT BRACKET
flashlight. Inspect element for cracked or melted sub-
strate.
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 Appropriate Diagnostic Informa-
tion) for test procedures.
INSTALLATION
NOTE: When assembling exhaust system do not
tighten clamps until all components are aligned and
clearances are checked.
(1) Assemble catalytic converter to exhaust mani-
fold connection. Use a new flange gasket.
(2) Tighten the catalytic converter to exhaust man-
ifold fasteners to 28 N·m (250 in. lbs.) (Fig. 9), (Fig.
10), (Fig. 11) or (Fig. 12).
(3) Install intermediate pipe and muffler (Refer to
11 - EXHAUST SYSTEM/INTERMEDIATE PIPE -
INSTALLATION) and (Refer to 11 - EXHAUST SYS-
TEM/MUFFLER - INSTALLATION).
(4) Working from the front of system; align each
component to maintain position and proper clearance
with underbody parts (Fig. 2). For clearance specifi-
1.6L
PT