Exhaust System Chrysler Crossfire I final

Scheme 1

A thin-wall air-gap insulated exhaust pipe leads to the three-way catalytic converter, which has an air-gap insulated housing. The air-gap insulation, whereby a steel shell is wrapped around the component, limits heat loss to hasten the catalytic converter action. The insulation also minimizes the need for insulation to protect the passenger compartment from excessive temperatures. A large - 812 cu. in, (13.3 L) - muffler is tuned to produce a sporty tone that meets pass-by noise levels in all markets. The rear-mounted muffler terminates in dual bright exhaust tips.

OPERATION

The exhaust emission control system is calibrated to meet ULEV I emission standards in California, Tier 2, BIN 8 emission standards in other U.S. states and Stage IV emission standards in Europe. The engine control computer and other hardware are the same for all markets, but there is some difference in the software depending on local emissions requirements. Dual ignition reduces hydrocarbon emissions (unburned fuel) released by the engine to the catalytic converter by 20 percent compared to single ignition systems. This reduction is especially beneficial during the cold start and warm up phases of operation, which is when a majority of the tailpipe emissions occur on today's cars because the catalytic converter has not yet reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the vehicle.

DIAGNOSIS AND TESTING

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 damage.

ALIGNMENT

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, insulators, 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.

TORQUE

TORQUE SPECIFICATIONS

REMOVAL

Scheme 2

1. Raise and support the vehicle.
2. Disconnect the oxygen sensor harness connectors (6 and 7).
3. Support the exhaust system.
4. Remove the bolts at the left and right side exhaust manifold flanges (8 and 9).
5. Remove the center exhaust flange bolts (3).
6. Remove the left and right side exhaust pipes from the vehicle (5 and 10).
7. Remove the bolts (1) at the right side exhaust pipe flange.

INSTALLATION

Note. Inspect the exhaust manifold flange surface. Replace as required.

1. Install bolts at right side exhaust pipe flange (11). Tighten to 20 N.m (15 ft. lbs.).
2. Position and support the front exhaust pipes in the vehicle.
3. Install bolts at the left and right exhaust manifold (8 and 9) flanges.
4. Install bolts at the center exhaust manifold flange (3).
5. Tighten exhaust manifold flange bolts to 20 N.m (15 ft. lbs.).
6. Tighten bolts at the center exhaust pipe flange to 20 N.m (15 ft. lbs.).
7. Connect oxygen sensor wiring harness connectors (6 and 7).
8. Route oxygen sensor wire harness in harness retainer.
9. Remove exhaust system support.
10. Lower the vehicle.

Scheme 3

1. Remove the muffler. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system) .
2. Remove the heat shield nuts (1) and the heat shield.

Scheme 4

1. Remove front exhaust section. See «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system__removal) .
2. Remove the heat shield nuts (1) and the heat shield.

INSTALLATION-REAR HEAT SHIELD

1. Install the heat shield and the nuts (1). Tighten the nuts to 10 N.m (89 in. lbs.).
2. Install the muffler. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system) .

INSTALLATION-FRONT HEAT SHIELD

1. Position the heat shield on the floor pan.
2. Install the heat shield nuts (1). Tighten the nuts to 10 N.m (89 in. lbs.).
3. Install the front exhaust section. See «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/exhaust/#exhaust-system__installation) .
4. Start the engine and check for exhaust leaks.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Raise and support vehicle.
2. Remove the rear support bracket. (Convertible only). Refer to «REMOVAL»(/chrysler/crossfire/i-final-2008-2008/remont/frames-subframes-crossmembers/#frame-bumpers) .
3. Support the rear section of the exhaust system.
4. Remove bolts (1) from the center connection flange.
5. Disconnect the ground (1) strap at the muffler.
6. Remove the pipe (1) from the exhaust hanger (2).
7. Pry the rubber exhaust hangers (1) off of the bracket.
8. Remove the muffler with the pipe from the vehicle.

1. Position the muffler section in the rubber exhaust hangers (1).
2. Install the bolts in the center exhaust flange (2). Tighten the bolts to 20 N.m (15 ft. lbs.).
3. Connect the ground strap (1) at the muffler and tail pipe. Tighten the ground strap bolt to 10 N.m (89 in. lbs.).
4. Remove the support.
5. Install the rear support bracket. (Convertible only). Refer to «INSTALLATION»(/chrysler/crossfire/i-final-2008-2008/remont/frames-subframes-crossmembers/#frame-bumpers) .
6. Lower the vehicle.

Scheme 9

1. Raise and support the vehicle.
2. Remove the bracket bolt (1).
3. Remove the bracket and the isolator (2) from the exhaust hanger.
4. Remove the isolator from the bracket.

1. Position the bracket and bolt on the vehicle.
2. Tighten the bolt to 20 N.m (15 ft. lbs.).
3. Install the isolator and hanger.
4. Lower the vehicle.

See also:
• REMOVAL
• REMOVAL
• REMOVAL
• INSTALLATION