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Parts and Accessories
Neon SRT-4 Exhaust Upgrade Removing the Stock Exhaust
- tools and materials used here:
- New exhaust system
- Catalytic converter
- Basic automotive tools (sockets, wrenches, screwdrivers, etc.)
- Torque wrench, 20"-long 3/8-drive extension
- 20" extension for bolts buried at the turbo
- Penetrating oil, Level, Straight-edge ruler
- Rubbing alcohol and clean, lint-free, 100%-cotton cloth
- Protective gloves and safety goggles
- Removing the Old Exhaust System
- The factory exhaust system on this car starts at the turbo, and runs through a down-pipe, catalytic converter, exhaust pipe and resonators, and extends over the suspension before it connects to the tailpipe at the rear. There is no muffler on this car since the small-gauge exhaust system and turbo act as a restriction -- which essentially serves the same purpose as a muffler. Following are the steps for removing the stock exhaust-system.
- To begin, get the car up on a lift. Working with a lift will make this particular job much easier.
- If a lift is not available, raise the car up with about two feet of clearance underneath using three-ton jack stands and floor jacks. These can be rented if you don't have any. Check your manual to find out the best jack-stand contact points on your car. On ours, it's the pinch-rails closest to the wheels.
- Note:: Make sure you on level ground when jacking up the car and jack it up in stages.
- Spray penetrating fluid on exhaust bolts. Allow the fluid to soak in.
- To remove the old exhaust system, begin at the tailpipe and loosen the band clamp that connects the tailpipe to the extension pipe.
- Apply pressure with channel locks to start the rubber tailpipe-isolator over the hangar flange.
- Slide the rubber isolator completely off the hanger by hand.
- Use the same technique to remove the driver's side isolator while your helper supports the tailpipe from the rear.
- Separate the tailpipe from the extension pipe, and set it aside.
- Use channel locks to get the isolator started over the flange. Then pull the isolator off by hand and keep them handy to be used on the new system.
- Once the tailpipe and the rear isolators are removed, the extension pipe is next. Remove it by first loosening the band clamp at the front-end, and then pop off the isolator at the rear of the pipe.
- With a person at each end, twist and pull the extension pipe towards the rear of the car to disconnect it from the down-pipe. Pull the pipe forward and down to remove it from the car. You'll have to twist it a little to clear the rear suspension component.
- Once the extension pipe is out of the way you can remove the oxygen sensors and begin on the down-pipe. Unplug the oxygen sensor and carefully remove it from the down-pipe with a 7/8" open-end wrench and set aside.
- Tip: As oxygen sensors age, they can provide false readings, producing poor emissions quality and engine performance through a rich fuel-air ration.
- Remove the four nuts holding the down-pipe in place. The down-pipe and cat will slide out.
- Inspect the composite exhaust gasket for any breaks or burned areas. If it looks good you can reuse it with the new system.
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