Caravan AWD V6-201 3.3L (1991)
Exhaust Pipe: All Technical Service Bulletins
Exhaust - Hissing or Puffing Noises
DATE: Mar. 24, 1995
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-94 REV. A DATED OCT. 28, 1994 WHICH SHOULD BE NOTED IN
YOUR FILES, AND THE 1994 TECHNICAL SERVICE BULLETIN MANUAL (TO BE RELEASED ON OR ABOUT MAR. 31, 1995 AS
PUBLICATION NO. 81-699-95054). THIS BULLETIN ADDS MODELS. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
**1991 - 1995
(AS) Town & Country/Caravan/Voyager (Equipped with V-6 Engine)
1992 - 1995
(ES) Chrysler Voyager (European Market Equipped with V-6 or
Diesel Engine) **
Exhaust noise that can be described as a "hissing" or "puffing" sound on acceleration or under moderate to heavy engine load, coming from the front of
the vehicle, and/or a squeak/chirp noise may be heard during engine start up or shut down or when shifting gears.
Exhaust Seal Ring
Exhaust Flange Springs
This bulletin involves replacement of the exhaust seal ring, exhaust flange springs and sizing the catalytic converter inlet pipe to provide a better fit of
the exhaust seal ring.
Raise the vehicle on an appropriate hoist and if equipped, disconnect the downstream oxygen sensor connector.
Remove the two shoulder bolts, exhaust flange springs and nuts retaining the front catalytic converter pipe to the exhaust manifold. Discard the old
Loosen the clamp between the catalytic converter and the intermediate exhaust pipe and remove the catalytic converter from the vehicle.
Replace the exhaust seal ring with revised P/N 4546818.
With the revised exhaust seal ring in place on the catalytic converter inlet pipe, use a manual multi-segment pipe expander to round-up the inlet
pipe diameter of the catalyst so that the seal ring is "snug" to the pipe. The seal ring should still rotate on the pipe but not spin freely. Expand only
the first 13 mm (approx. 1/2") of the inlet pipe.
BE CAREFUL NOT TO EXPAND THE PIPE TOO FAR AS THE SEAL RING COULD CRACK. SHOULD THE SEAL RING CRACK, BOTH
THE CATALYTIC CONVERTER AND SEAL RING WILL HAVE TO BE REPLACED. A HYDRAULIC PIPE EXPANDER IS NOT
RECOMMENDED FOR THIS PROCEDURE.
Install the catalytic converter to the vehicle and install the inlet pipe to the exhaust manifold using revised exhaust flange springs, P/N 4427299.
If equipped, connect the downstream oxygen sensor connector and lower the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
Labor Operation No: