Exhaust System: Removal & Installation Dodge Dart PF

REMOVAL

Note. Some service procedures require the removal of the entire exhaust system in order to gain better access to certain components for removal and installation. The following procedure explains how to remove the entire exhaust system. Refer to specific procedures if replacing individual exhaust components.

1. Raise vehicle on hoist and apply penetrating oil to fasteners that connect the exhaust system to the exhaust manifold/cross-under pipe clamp.
2. Disconnect downstream oxygen sensor connector.
3. Remove fasteners that attach exhaust system to exhaust manifold /cross-under pipe clamp. 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.
4. Remove support isolators from muffler supports.
5. Remove exhaust system from vehicle.

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 for the following reasons

1. To insure proper alignment with other parts in the system.
2. Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could affect emissions and performance.

INSTALLATION

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

1. Loosely install fasteners that attach exhaust system to exhaust manifold/cross-under pipe.
2. Install support isolators to exhaust system supports.
3. Align exhaust system to maintain position and proper clearance with underbody parts. All support isolators should have equal load on them. Tighten fasteners that attach exhaust system to exhaust manifold/cross-under pipe to 19 N.m (168 in. lbs.). Tighten the flange fasteners to 19 N.m (168 in. lbs.).
4. Reconnect the downstream oxygen sensor connector.
5. Lower vehicle.
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 adjustments, if needed.

1. Install the new converter to turbo seal ring (1).
2. Install the catalytic converter assembly (3).
3. Position the exhaust manifold shield and install the 2 bolts and one new nut.
4. Tighten the shield bolts and nut to 9 N.m (80 in. lbs.). CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the hourglass shaped center block. Once this occurs, the clamp has lost clamping force and must be replaced.
5. Install the catalytic converter v-clamp (2) at the turbocharger (1).
6. Tighten clamp to 8 N.m (71 in. lbs.).
7. Connect the oxygen sensor connector.
8. Install the catalytic converter lower support bracket (2).
9. Install and tighten the bracket bolts (3) to 56 N.m (41 ft. lbs.).
10. Install a new converter to pipe gasket.
11. Install the front exhaust pipe.
12. Install the front exhaust pipe gasket. Install the front exhaust pipe nuts to the converter outlet.
13. Tighten the front exhaust pipe nuts to 56 N.m (41 ft. lbs.).
14. Install the front exhaust pipe support bolt (2). Tighten to 56 N.m (41 ft. lbs.).
15. Install the exhaust flange gasket and nuts (1). Tighten the nuts to 69 N.m (51 ft. lbs.).
16. Install the Charge Air Cooler (CAC) supply hose (5) to the turbocharger.
17. Install the CAC hose clamp and tighten.
18. Install the catalytic converter heat shield (3).
19. Tighten the nuts and bolts to 8 N.m (71 in. lbs.). Care must be taken when tightening the shield bolts. If torque value is not correct, noise will occur.
20. Connect the upstream and downstream oxygen sensor connectors.
21. Connect the negative battery cable.

Scheme 10

Scheme 11

Scheme 12

1. Raise vehicle on hoist.
2. Remove the cross-under pipe (2) rear flange nuts (3).
3. Separate the exhaust system pipe (1) from cross-under pipe.
4. Remove the cross-under (2) center support bolt (1).
5. Disconnect the O2 sensor (2) electrical connector.
6. Remove the upper cross-under pipe flange nuts (1).
7. Remove the cross-under pipe from the vehicle.

1. Install new gasket to lower part of rear catalytic converter. If installing new cross-under pipe (3), transfer oxygen sensors (2) to new pipe.
2. Loosely install cross-under pipe to catalytic converter. Snug nuts (1) up equally using hand pressure.
3. Connect exhaust system pipe (1) to cross-under pipe (2). Tighten nuts (3) to 28 N.m (21 ft. lbs.).
4. Reconnect downstream oxygen sensor connectors.
5. Install the center support bolt (1). Tighten bolt to 28 N.m (21 ft. lbs.).
6. Tighten the 2 nuts for cross-under pipe to catalytic convertor flange to 28 N.m (21 ft. lbs.).
7. Lower vehicle.
8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
9. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.

For removal of the exhaust resonator. Refer to MUFFLER, EXHAUST, REMOVAL .

For installation of the exhaust resonator. Refer to MUFFLER, EXHAUST, INSTALLATION .