2000 DODGE NEON Service Repair Manual

DIAGNOSIS AND TESTING
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE
EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or broken. 1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace gasket.
3. Exhaust Flex joint to manifold leak. 3. Tighten fasteners or replace gasket.
4. Exhaust flex joint. 4. Replace catalytic converter assembly.
5. Pipe and shell noise from front exhaust
pipe.5. Characteristic of single wall pipes.
EXCESSIVE
EXHAUST NOISE1. Leaks at pipe joints. 1. Tighten or replace clamps at leaking
joints.
2. Burned, blown, or rusted out exhaust
pipe or muffler.2. Replace muffler or exhaust pipes.
3. Restriction in muffler or tailpipe. 3. Remove restriction, if possible or replace
as necessary.
4. Catalytic converter material in muffler. 4. Replace muffler and converter assembly.
Check fuel injection and ignition systems for
proper operation.
REMOVAL AND INSTALLATION
EXHAUST PIPE AND MUFFLER
REMOVAL
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 OPERATING TIME.
(1) Raise vehicle on hoist and apply penetrating oil
to band clamp fastener of component being removed.
NOTE: Do not use petroleum-based lubricants
when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part.
A suitable substitute is a mixture of liquid dish
soap and water.
(2) Remove exhaust system ground strap.
(3) Loosen band clamp and remove support isola-
tors at muffler. Remove muffler from exhaust pipe
(Fig. 7).(4) Loosen band clamp at the catalytic converter to
intermediate pipe joint (Fig. 7)
(5) Remove intermediate pipe support isolator.
Separate at slip joint and remove intermediate pipe
(Fig. 7).
(6) Clean ends of pipes and muffler to assure mat-
ing of all parts. Discard broken or worn isolators,
rusted or overused clamps, supports, and attaching
parts.
NOTE: When replacement is required on any com-
ponent of the exhaust system, you must use origi-
nal equipment parts (or their equivalent).
INSTALLATION
When assembling exhaust systemdo nottighten
clamps until components are aligned and clearances
are checked.
(1) Assemble intermediate pipe to catalytic con-
verter and the isolator support to the underbody (Fig.
7).
(2) Install the muffler to intermediate pipe and the
isolator supports to the underbody.
(3) Working from the front of system; align each
component to maintain position and proper clearance
with underbody parts (Fig. 9). Tighten band clamps
to 47 N´m (35 ft. lbs.) (Fig. 8).
11 - 4 EXHAUST SYSTEMPL

CAUTION: Band clamps should never be tightened
such that the two sides of the clamps are bottomed
out against the center hourglass shaped center
block. Once this occurs, the clamp band has been
stretched and has lost its clamping force and must
be replaced.*
NOTE: Maintain proper clamp orientation when
replacing with new clamp.
(4) Connect the exhaust system ground strap.
Fig. 7 Catalytic Converter, Intermediate Pipe, and Muffler
1 ± CATALYTIC CONVERTER
2 ± INTERMEDIATE PIPE3 ± MUFFLER
4 ± ISOLATORS
* To replace the band clamp; remove the nut and
peel back the ends of the clamp until spot weld
breaks.
Fig. 8 Band Clamp
1 ± CLAMP SIZE
2 ± TORQUE SPECIFICATION
PLEXHAUST SYSTEM 11 - 5
REMOVAL AND INSTALLATION (Continued)

Fig. 9 Exhaust Clearance
11 - 6 EXHAUST SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

CATALYTIC CONVERTER
REMOVAL
WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
NOTE: Vehicles equipped with the ULEV emission
package are equipped with an additional catalytic
converter that is integral to the exhaust manifold.
Refer to Exhaust Manifold in Group 9, Engine for
procedure.
(1) Remove muffler and exhaust pipe. Refer to pro-
cedure in this section.
(2) Disconnect downstream oxygen sensor electri-
cal connector.
(3) Remove exhaust manifold support bracket
(Federal and LEV only) (Fig. 10).
(4) Remove catalytic converter to exhaust manifold
attaching fasteners and remove converter from vehi-
cle (Fig. 11) or (Fig. 12).
(5) Remove and discard flange gasket.
NOTE: When replacement is required on any com-
ponent of the exhaust system, original equipment
parts (or equivalent) must be used.
INSTALLATION
NOTE: When assembling exhaust system do not
tighten clamps until all components are aligned and
clearances are checked.(1) Assemble catalytic converter to exhaust mani-
fold connection. Use a new flange gasket.
1 ± HEAT SHIELD
2 ± FLOOR PAN
3 ± BAND CLAMP
4 ± FLOOR PAN
5 ± TANK STRAP
6 ± FUEL TANK
7 ± SPARE TIRE TUB
8 ± REAR SUSPENSION CROSSMEMBER
9 ± FLOOR PAN
10 ± SPARE TIRE TUB
11 ± MUFFLER12 ± BUMPER BEAM
13 ± HEAT SHIELD
14 ± OXYGEN SENSOR CLEARANCE (LEV)
15 ± FLOOR PAN
16 ± FEDERAL & LEV
17 ± OXYGEN SENSOR CLEARANCE (FEDERAL)
18 ± HEAT SHIELD
19 ± FLOOR PAN
20 ± CROSSMEMBER
21 ± TAIL PIPE
22 ± FASCIA
Fig. 10 Exhaust Manifold Support BracketÐFederal
& LEV
1 ± BRACKET
2 ± BOLT (M10)
3 ± BOLT (M12)
4 ± NUT
Fig. 11 Catalytic Converter to Exhaust Manifold
ConnectionÐFederal & LEV
1 ± PRESSED-IN STUDS
2 ± NUTS
3 ± GASKET
PLEXHAUST SYSTEM 11 - 7
REMOVAL AND INSTALLATION (Continued)

(2) Install exhaust manifold support bracket (Fed-
eral and LEV only). Tighten M10 bolt to 54 N´m (40
ft. lbs.), M12 bolt to 95 N´m (70 ft. lbs.), and nut to
28 N´m (250 in. lbs.).
(3) Install bolt attaching manifold support bracket
to the heat shield (Federal and LEV only). Tighten
bolt to 28 N´m (250 in. lbs.).
(4) Assemble muffler and exhaust pipe to catalytic
converter. Install muffler and pipe support isolators
to the underbody.
(5) Tighten the catalytic converter to exhaust man-
ifold fasteners to 28 N´m (250 in. lbs.) (Fig. 11) or
(Fig. 12).
(6) Working from the front of the systemÐalign
each component to maintain position and proper
clearance with under body components. Tighten all
slip joint band clamps to 47 N´m (35 ft. lbs.).
CAUTION: Band (Torca) clamps should never be
tightened such that the two sides of the clamps are
bottomed out against the center hourglass shaped
center block. Once this occurs, the clamp has lost
clamping force and must be replaced.
(7) If removed, install downstream oxygen sensor.
(8) Connect downstream oxygen sensor electrical
connector.
CLEANING AND INSPECTION
EXHAUST SYSTEM
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.
ADJUSTMENTS
EXHAUST SYSTEM ALIGNMENT
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard
to distinguish from other chassis noises. Inspect
exhaust system for broken or loose clamps, heat
shields, insulators, and brackets. Replace or tighten
as necessary. It is important that exhaust system
clearances and alignment be maintained.
Perform the following procedures to align the
exhaust system. Refer to (Fig. 9) for clearance speci-
fications:
(1) Loosen clamps and support brackets.
(2) Align the exhaust system starting at the front,
working rearward.
(3) Tighten all clamps and brackets once align-
ment and clearances are achieved.
SPECIFICATIONS
TORQUE SPECIFICATION CHART
Fig. 12 Catalytic Converter to Exhaust Manifold
ConnectionÐULEV
1 ± PRESSED-IN NUTS
2 ± GASKET
3 ± BOLTS
DESCRIPTION N´m Ft.
Lbs.In.
Lbs.
Band ClampsÐFastener 47 35 Ð
Catalytic Converter to Exhaust
Manifold FlangeÐFasteners28 Ð 250
11 - 8 EXHAUST SYSTEMPL
REMOVAL AND INSTALLATION (Continued)

FRAME AND BUMPERS
TABLE OF CONTENTS
page page
BUMPERS................................ 1FRAMES................................. 5
BUMPERS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
BUMPER FASCIA..........................1
REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA...................3FRONT BUMPER REINFORCEMENT...........3
REAR BUMPER FASCIA....................4
REAR BUMPER REINFORCEMENT............4
DESCRIPTION AND OPERATION
BUMPER FASCIA
The bumper fascia is a decorative covering that is
placed over the bumper reinforcement.
FRONT BUMPER FASCIA
1 ± FRONT BUMPER FOAM
2 ± AIR DAM
3 ± FRONT BUMPER FASCIA
4 ± FASCIA TO BODY RETAINER5 ± ATTACHING NUT
6 ± FRONT BUMPER FASCIA
7 ± FRONT BUMPER STRIP
PLFRAME AND BUMPERS 13 - 1

FRONT BUMPER REINFORCEMENT
1 ± FRONT BUMPER REINFORCEMENT
REAR BUMPER FASCIA
1 ± REAR BUMPER FOAM
2 ± REAR BUMPER REINFORCEMENT3 ± REAR FASCIA TO BODY RETAINER
4 ± REAR FASCIA
REAR BUMPER REINFORCEMENT
1 ± REAR BUMPER REINFORCEMENT
13 - 2 FRAME AND BUMPERSPL
DESCRIPTION AND OPERATION (Continued)

REMOVAL AND INSTALLATION
FRONT BUMPER FASCIA
REMOVAL
(1) Remove nuts attaching front bumper fascia to
bottom of fender flange (Fig. 1).
(2) Remove fasteners attaching fascia to bumper
reinforcement forward of radiator.
(3) Remove fasteners attaching fascia to bottom of
bumper reinforcement.
(4) Remove air dam fasteners from crossmember.
(5) Remove splash shield attaching screws.
(6) Remove fascia from vehicle.
INSTALLATION
(1) Position fascia on vehicle.
(2) Install splash shield attaching screws.
(3) Install air dam fasteners to crossmember.
(4) Install fasteners attaching fascia to bottom of
bumper reinforcement.
(5) Install fasteners attaching fascia to bumper
reinforcement forward of radiator.
(6) Install nuts attaching front bumper fascia to
bottom of fender flange.
FRONT BUMPER REINFORCEMENT
REMOVAL
(1) Remove front fascia.
(2) Support bumper reinforcement on a suitable
lifting device.(3) Remove nuts attaching reinforcement to the
rail assembly (Fig. 2).
(4) Remove bumper reinforcement from vehicle.
INSTALLATION
(1) Place bumper reinforcement in position.
(2) Support bumper reinforcement on a suitable
lifting device.
(3) Install nuts attaching reinforcement to rail
assembly.
(4) Install front fascia.
Fig. 1 Front Bumper Fascia
1 ± FRONT FASCIA
2 ± FASCIA TO REINFORCEMENT BRACKET
Fig. 2 Front Bumper Reinforcement
1 ± RAIL ASSEMBLY
2 ± FRONT BUMPER REINFORCEMENT
PLFRAME AND BUMPERS 13 - 3