SUBJECT: Excessive Exhaust Noise / Vibration During / After Underbody Contact With Moisture
NO: 11-02-98
GROUP: Exhaust
DATE: Feb. 6, 1998

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-04-96 DATED JUNE 26, 1996 WHICH SHOULD BE NOTED IN THE 1996 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-97010). A NEW HEAT SHIELD AND REPAIR PROCEDURE ARE PROVIDED IF ALIGNMENT CANNOT BE ACCOMPLISHED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
MODELS: 1995 - 1996 (PL) Neon
SYMPTOM/CONDITION: Excessive exhaust noise and/or vehicle vibration during/after vehicle is driven through puddles or underbody contact with snow/slush. The intermediate pipe may be contacting the tunnel heat shield when it is cooled from the water/snow contact.

CAUTION:

TO PREVENT SERIOUS INJURY FROM HOT EXHAUST COMPONENTS, ENSURE THAT THE VEHICLE HAS NOT BEEN DRIVEN AND THE EXHAUST IS COLD BEFORE INSPECTION AND REPAIR.
DIAGNOSIS: With the vehicle on a suitable hoist, inspect the tunnel heat shield for any marks where the intermediate pipe has made contact. If the pipe or heat shield show signs of contact, or the pipe appears to be out of alignment with the tunnel, proceed to the repair procedure.
PARTS REQUIRED:
AR 04495951
**AR 05278028AB Isolator, Exhaust Rubber Heat Shield**
REPAIR PROCEDURE:
This bulletin involves aligning the exhaust pipe in the tunnel and straightening the tunnel heat shield.
  1. Measure the clearance between the intermediate("l") pipe and shield/floor pan in the areas of contact. Record this data on the repair order for future use.
  2. Inspect the catalyst assembly to ensure that the alignment button is fitted into the notch on the " 1" pipe (figure 1 )
  3. If the alignment button is fitted into the notch and the "I" pipe is not in the center of the tunnel, remove the alignment button to allow centering of the "I" pipe in the tunnel by the following procedure:
    Separate the "I" pipe from the portion of the pipe with the alignment button.
    Using a grinder or chisel, remove the alignment button to allow the pipe to turn easily within the "I" pipe.
  4. Inspect the rubber isolators on the "I" pipe and muffler for side to side movement, by passing on the pipe. The rubber isolators are designed for forward and rearward movement only. If the exhaust system cannot be centered as described in steps 2and 3, replace the rubber isolator with P/N 04495951.
  5. If the "I" pipe is correctly aligned down the center of the tunnel and still contacts the heat shield, the heat shield must be replaced.
  6. ***Remove the rear three bolts of the heat shield (Figure 2).
  7. Loosen the front two bolts and slide the heat shield off (Figure 2).
  8. Slide the new heat shield (P/N 05278028AB) into place over the two front bolts.Ensure that the heat shield is fully seated on the two bolts.
  9. Install the rear center bolt and torque to 3.7 N m (33 In.-lb.).
  10. Torque the two front bolts to 3.7 N m (33 In.-lb.).
  11. Install the remaining two rear bolts and torque to 3.7 N m (33 In.-lb.).
  12. Install the intermediate pipe, if removed, and torque clamps to 74.5 N m (55 ft.lb.).
  13. Test drive the vehicle and listen for the noise/vibration. If the noise/vibration is still apparent, proceed to step 14. If the noise/vibration is gone, no further action is needed.**
  14. Inspect the areas of contact and bend the shield to provide more clearance:
    • Measure between the "l" pipe and the heat shield in the areas showing contact marks, there should be a minimum clearance of 25mm (Figure 3).
      In the areas that are out of specification, use a pair of pliers to bend the heat shield to provide the proper clearance (Figure 3).
    • Measure between the heat shield and the floor pan in the areas showing contact marks, there should be a minimum of 5mm clearance (Figure 3)
    • In the areas that are out of specification, use a pair of pliers to bend the heatshield to provide the proper clearance (Figure 3).

      CAUTION: DO NOT BEND THE HEAT SHIELD TO THE EXTENT THAT IT CONTACTS THE BODY OR BECOMES LOOSE.
POLICY: Reimbursable within the provisions of the warranty.