Dodge Intrepid - Exhaust System

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
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. EGR tube to manifold gasket
leakage.
3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.
4. Tighten fasteners or replace
gasket.
5. Exhaust to manifold leak. 5. Tighten or replace V-Band Clamp.
6. Pipe and shell noise from front
exhaust pipe.
6. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.
2. Replace exhaust module, rear
resonator/tailpipe assembly or
exhaust pipe with catalytic converter
assembly.
3. Burned or rusted out
resonator(s).
3. Replace resonator assembly.
4. Restriction in exhaust system. 4. Remove restriction if possible, or
replace components as necessary.
5. Converter material in muffler or
resonators.
5. Replace muffler, resonators and
converter assemblies. Check fuel
injection and ignition systems for
proper operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIIt and PEP
module pressure tester.
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.
(1) Disconnect and remove the upstream (before
catalytic converter) oxygen sensor. (Refer to 14 -
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR -
REMOVAL)
(2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
(3) Connect the Low Pressure Sensor (15 psi)
CH7063 to the back pressure fitting.
(4) Following the PEP module instruction manual,
connect all required cables to the DRB IIIt and PEP
module. Select the available menu options on the
DRBIIIt display screen for using the digital pressure
gauge function.
(5) Apply the park brake and start the engine.
(6) With transmission in Park or Neutral, raise
engine speed to 2000 RPM. Monitor the pressure
readings on the DRBIIIt. Back pressure should not
exceed specified limit. Refer to specification in table
below EXHAUST BACK PRESSURE LIMITS .
NOTE: For applications with dual catalytic convert-
ers, repeat test on opposite converter using the
previous steps.
LH EXHAUST SYSTEM 11 - 3
EXHAUST SYSTEM (Continued)