Exhaust System: Other Dodge Dart PF

RESTRICTION CHECK

Exhaust system restriction can be checked by measuring back pressure using the scan tool and PEP module pressure tester.

1. Disconnect and remove the upstream (before catalytic converter) oxygen sensor. Refer to «SENSOR, OXYGEN, REMOVAL»(ref-646230-S13401513602014072800000) .
2. Install the Exhaust Back Pressure Fitting Adaptor (special tool #CH8519, Hose, Exhaust Back Pressure).
3. Connect the Low Pressure Sensor (15 psi) CH7063 to the back pressure fitting.
4. Following the PEP module instruction manual, connect all required cables to the scan tool and PEP module. Select the available menu options on the scan display screen for using the digital pressure gauge function.
5. Apply the park brake and start the engine.
6. With transmission in Park or Neutral, raise engine speed to 2000 RPM. Monitor the pressure readings on the scan. Back pressure should not exceed specified limit. Refer to specification in table below. NOTE: For applications with dual catalytic converters, repeat test on opposite converter using the previous steps.
7. If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures. Refer to «CONVERTER, CATALYTIC, INSPECTION»(ref-646259-S21736914332014072800000) . Replace component(s) as necessary.

EXHAUST BACK PRESSURE LIMITS

1.4L

Note. When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used.

1. Raise and support the vehicle.
2. Remove the nuts (2) holding front to rear pipe. CAUTION: Do not use any tools to remove the rubber isolators - remove by hand only. Soapy water may be used to assist removal/installation of isolators. DO NOT use a petroleum-based lubricant on the isolators, as damage to the rubber material can occur.
3. With the help of an assistant remove front (3) and rear (4) support isolators from muffler supports.
4. Lower the front section of the exhaust pipe, move the muffler assembly forward, then down and out of the exhaust tips being careful not to damage the exhaust tips.
5. Remove and discard the exhaust flange gasket.

2.0L/2.4L

Note. When replacement is required on any component of the exhaust system, it is most important that original equipment parts (or their equivalent) be used.

1. Raise and support the vehicle.
2. Remove the nuts (2) holding front to rear exhaust pipes together. CAUTION: Do not use any tools to remove the rubber isolators-remove by hand only. Soapy water or silicone based lubricant spray may be used to assist removal/installation of isolators. DO NOT use a petroleum based lubricant on the isolators, as damage to the rubber material can occur.
3. With the help of an assistant remove front (3) and rear (4) support isolators from muffler supports.
4. Remove the one muffler/resonator assembly.
5. Remove and discard the exhaust flange gasket.

Note. Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

1. Install a new flange gasket over exhaust pipe studs.
2. Position muffler and resonator assembly onto the front pipe, being careful not to damage the exhaust tips.
3. Install the front (3) and rear (4) support isolators.
4. Align muffler and resonator assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them.
5. Install the nuts (2) holding the front to rear pipe and torque to 19 N.m (168 in. lbs.).
6. Lower vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

Note. Always work from the front to rear of exhaust system when aligning and tightening exhaust system components.

1. Install a new flange gasket over exhaust pipe studs.
2. Position muffler and resonator assembly onto the front pipe.
3. Install front (3) and rear (4) support isolators.
4. Align muffler and resonator assembly to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them.
5. Install the nuts (2) holding the front to rear pipe and torque to 19 N.m (168 in. lbs.).
6. Lower vehicle.
7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
8. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.