DIY Network

Neon SRT-4 Exhaust Upgrade: Removing the Stock Exhaust From "Tricked Out" episode DTRK-107

In this Tricked Out episode, Andrew Totolos and guest expert Gary Howell install a performance exhaust system on an already beefed-up Dodge Neon SRT-4. In this first segment, Andrew introduces the project car and work gets underway removing the factory exhaust system.

The project car: Dodge Neon SRT-4

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Performance specialist Gary Howell

Tools and materials used in this episode:

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 (figure A). 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 (figure B). 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.

• Safety Alert: Make sure you on level ground when jacking up the car and jack it up in stages.

  Figure A

  Figure B

  
  

• 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 (figure C).

• Apply pressure with channel locks to start the rubber tailpipe-isolator over the hangar flange (figure D).
  
  
• Slide the rubber isolator completely off the hanger by hand.

  Figure C

  Figure D

  
  

• Use the same technique to remove the driver's side isolator while your helper supports the tailpipe from the rear (figure E).

• Separate the tailpipe from the extension pipe, and set it aside.

• Use channel locks to get the isolator started over the flange (figure F). Then pull the isolator off by hand and keep them handy to be used on the new system.

  Figure E

  Figure F

  
  

• 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 (figure G), 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 (figure H).

  Figure G

  Figure H

  
  

• 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 (figure I) and carefully remove it from the down-pipe with a 7/8" open-end wrench (figure J) 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.

  Figure I

  Figure J

  
  

• Remove the four nuts holding the down-pipe in place (figure K). The down-pipe and cat will slide out.

• Inspect the composite exhaust gasket (figure L) for any breaks or burned areas. If it looks good you can reuse it with the new system.

  Figure K

  Figure L

  
  

RESOURCES :

Howell Automotive
Website: www.howellautomotive.com

Racing Innovations, Inc.
Website: www.racinginnovations.com

Thermal Research and Development
Website: www.thermalrd.com

Bend-Pak
Website: www.bendpak.com