DIY Network

Neon SRT-4 Exhaust Upgrade: Installing the Stainless-Steel Exhaust From "Tricked Out" episode DTRK-107

	Andrew installs the new exhaust system on the SRT-4.
	The old exhaust system and the new

Now that the factory-installed exhaust system has been removed, Andrew and Gary get to work installing the new high-performance system.

Tools and materials used in this project:

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

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Installing the New Exhaust

• To remove the old system, we worked from the back of the car to the engine. Now we're going to reverse that starting with the high-flow cat and working to the exhaust tips.

• To install the new down-pipe/cat assembly (figure A), hang the Kevlar exhaust gasket from the original exhaust system back on the exhaust manifold bolts (figure B).

  Figure A

  Figure B

  
  

• Slide the down-pipe assembly into place and start the nuts by hand.

• You'll need a 20"-long 3/8"-drive extension to reach the nuts with a torque wrench (figure C). Torque them down to 21-foot pounds each.

• Connect the extension pipe to the down-pipe with the band clamp in place but not tightened.

• Install the second extension pipe over the rear suspension components (figure D) and insert the extension pipe hanger into the support isolator.

  Figure C

  Figure D

  
  

• Insert an exhaust gasket between the two extensions (figure E) and loosely install the three bolts that hold the pieces together. Don't forget that each bolt receives a lock washer to hold the nut in place.

• The isolators that were removed from the tailpipe of the factory-installed system slide onto the hangers on the new muffler. Spray them with penetrating fluid for lubrication and slide them into place (figure F).

  Figure E

  Figure F

  
  

• Then with your helper lending a hand, lift the muffler into position (figure G) and slide the isolators onto the car-side exhaust mounts.

• The design of this muffler requires the driver's-side isolator to be installed first, so be sure to check the hangar positions before sliding the isolators into place (figure H).

  Figure G

  Figure H

  
  

  Figure I

• Install another exhaust gasket (figure I) and three more bolts to loosely attach the muffler to the extension pipe.

• Tip: Keep in mind that, due to the clearances around the exhaust connections, you may have to install bolts from the front or back of the flange, but whenever possible install exhaust bolts so that they face down. That way if you nut happens to fall off, gravity will help hold the bolt in place until the nut can be replaced.
  

• Slide the driver's-side tailpipe onto the muffler with the band clamp in place (figure J) and bolt the alignment tabs together to keep everything in line.

• With the tabs locked down, the driver's-side tailpipe band clamp can be tightened (figure K).

  Figure J

  Figure K

  
  

  	Figure L

• Attach the passenger-side exhaust tip (figure L) with a band clamp.

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