DIY Network

Neon SRT-4 Exhaust Upgrade: Completion and Performance Test From "Tricked Out" episode DTRK-107

In this final segment, Andrew and Gary complete the installation of the new high-performance exhaust system. Now that the system is installed, they line everything up and tighten it down. Finally a performance test is conducted to check acceleration and torque following the upgraded for comparison to baseline results.

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

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Finishing Touches

• Use an Allan wrench to remove the oxygen-sensor plug.

• With the plug removed, insert the original factory oxygen sensor (figure A).

• Tighten it down with an open-end wrench (figure B).

• Plug the sensor back into the crossmember and make sure that the safety plug locks into place.

  Figure A

  Figure B

  
  

• Have a friend hold the rear of the extension pipe in place as you tighten the first band clamp (figure C).

• Tighten the three bolts at the connection flange between the two extension pipes.

• Tigten the three remaining bolts at the connection flange between the second extension pipe and the muffler assembly (figure D).

  Figure C

  Figure D

  
  

• Center the exhaust tips, using your fingers to check the distance between the exhaust tips and the bumper cutouts on each side (figure E).

• Use a straightedge to measure how far the driver's-side exhaust tip sticks out from the bumper (figure F) and adjust the passenger-side tip to match.

  Figure E

  Figure F

  
  

• Finally, tighten the band clamp at the second tip (figures G and H), and the new exhaust is installed.

  Figure G

  Figure H

  
  

  	The Dyno results, before . . .
  	and after.