Intermediate Pipe: Installation

WARNING: This page is about a different car, the 2005 Dodge SX, 2005 Dodge SRT-4, and 2005 Dodge Neon. However, it is still accessible from the selected car via links, so may be relevant.

When assembling exhaust system do not tighten clamps until components are aligned and clearances are checked.

Assemble intermediate pipe to catalytic converter and the isolator support to the underbody. See Figure.
Install the muffler to intermediate pipe and the isolator supports to the underbody.
Working from the front of system; align each component to maintain position and proper clearance with underbody parts. (Refer to EXHAUST SYSTEM - ADJUSTMENTS)
Tighten all band clamps to 47 N.m (35 ft. lbs.). See Figure.
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: *To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks.

NOTE: Maintain proper clamp orientation when replacing with new clamp.
Connect the exhaust system ground strap.
Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary.
Check the exhaust system for contact with the body panels. Make the necessary adjustments, if needed.