Removal - Exhaust System; Inspection; Installation - Exhaust System - Dodge Intrepid Service Manual

11 - 4 EXHAUST SYSTEM
EXHAUST SYSTEM (Continued)
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
EXHAUST BACK PRESSURE LIMITS
Exhaust Back Pressure Limit (Max)
Vehicle in Park/Neutral
(no load) RPM

REMOVAL - EXHAUST SYSTEM

WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
It is easier to service the exhaust system module
components (Fig. 1) or (Fig. 2), when system is
removed from the vehicle.
(1) Raise vehicle on hoist.
(2) Apply penetrating oil and loosen band clamps
at resonator connector.
(3) Separate exhaust module at front resonator
from the converter downpipes.
CAUTION: At this time, the exhaust system is held
by only isolators. Support the exhaust system
underneath the front resonator and the muffler
while the isolators are being removed. Do not use
any tools to remove the isolators, remove by hand
only. Soapy water or silicone-based spray may be
used to assist removal. Do Not use a petroleum-
based lubricant on the isolators. This will damage
the rubber material.
(4) Support exhaust system with jack stand.
(5) Remove screw
ground strap.
(6) Remove the rubber isolators from the rear sus-
pension crossmember and support brackets on body
(Fig. 3) and (Fig. 4).
(7) Lower exhaust system and lay on the ground.
NOTE: When replacement is required on any com-
ponent of the exhaust system, it is most important
that original equipment parts be used for the follow-
ing reasons:
3.45 Kpa (0.5 psi)
attaching exhaust
Fig. 3 Rubber Isolator Hanger to Body Support
1 - SUPPORT BRACKET
2 - ISOLATOR
3 - RESONATOR/PIPE
• To ensure proper alignment with other parts in
the system.
• Provide acceptable exhaust noise levels and does
not change exhaust system back pressure that could
affect emissions and performance.

INSPECTION

Inspect the exhaust pipes, catalytic converters,
muffler, and resonators for cracked joints, broken
welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
brackets, and insulators for cracks and corrosion
damage.
NOTE: Slip joint band clamps are spot welded to
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off.

INSTALLATION - EXHAUST SYSTEM

system
(1) Install and loose assemble the front resonator
to the converter pipes.
(2) Place the exhaust system on two supports (one
on side of muffler, one behind the resonator). Connect
the system to the converter pipes.
(3) Install the system's rubber isolators onto the
support brackets (Fig. 3) and (Fig. 4).
(4) Install exhaust system ground strap.
(5) Visually inspect the isolators. They should be
straight when viewing from front to back of the vehi-
cle. Working from the front of system, align each
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