Dodge Neon / Neon SRT-4. Manual — part 275
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(5) Connect the exhaust system ground strap.
(6) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(7) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
MUFFLER
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 isola-
tors as it may compromise the life of the part. A
suitable substitute is a mixture of liquid dish soap
and water.
(2) Remove exhaust system ground strap.
(3) Loosen band clamp and remove support isola-
tors at muffler. Remove muffler from exhaust pipe
(Fig. 12).
(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).
Fig. 12 EXHAUST SYSTEM COMPONENTS
1 - CATALYTIC CONVERTER
2 - INTERMEDIATE PIPE
3 - MUFFLER
4 - ISOLATORS
11 - 26
EXHAUST SYSTEM
PL/SRT-4
INTERMEDIATE PIPE (Continued)
INSTALLATION
When assembling exhaust system do not tighten
clamps until components are aligned and clearances
are checked.
(1) Install the muffler to intermediate pipe and the
isolator supports to the underbody.
(2) Working from the front of system; align each
component to maintain position and proper clearance
with underbody parts. (Refer to 11 - EXHAUST SYS-
TEM - ADJUSTMENTS)
(3) Tighten all band clamps to 47 N·m (35 ft. lbs.)
(Fig. 13).
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.*
NOTE: *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.
(4) Connect the exhaust system ground strap.
(5) Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary.
(6) Check the exhaust system for contact with the
body panels. Make the necessary ajustments, if
needed.
Fig. 13 Band Clamp
1 - CLAMP SIZE
2 - TORQUE SPECIFICATION
PL/SRT-4
EXHAUST SYSTEM
11 - 27
MUFFLER (Continued)
FRAME & BUMPERS
TABLE OF CONTENTS
page
page
BUMPERS
FRONT FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRONT BUMPER REINFORCEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . . . 5
REAR FASCIA
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR BUMPER REINFORCEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRAME
. . . . . . . . . . . . . . . . . . . 7
FRONT CROSSMEMBER
. . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . 14
BUMPERS
SPECIFICATIONS
TORQUE SPECIFICATIONS
DESCRIPTION
TORQUE
Front Bumper
Reinforcement Bolt
12 N·m (105 in. lbs.)
Rear Bumper
Reinforcement Bolt
10 N·m (90 in. lbs.)
Front Crossmember To
Side Rail Bolt
153 N·m (113 ft. lbs.)
Front Crossmember/
Control Arm To Side Rail
Bolt
244 N·m (1180 ft. lbs.)
FRONT FASCIA
REMOVAL
(1) Remove splash shield attaching screws.
(2) Remove fasteners attaching air dam to cross-
member (Fig. 1).
(3) SRT-4 vehicle remove four attaching screws
(Fig. 2).
(4) Disconnect
fog
lamp
wiring
harness,
if
equipped.
(5) Remove nuts attaching front bumper fascia to
bottom of fender flange. (Fig. 3), and (Fig. 4).
(6) Remove fascia from vehicle.
(7) SRT-4 vehicle remove the fascia to crossmem-
ber upper blockers from the fascia (Fig. 5).
PL/SRT-4
FRAME & BUMPERS
13 - 1
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