Exhaust System - Heat Melts Trunk Carpet

89chrysler06

Models

1987-1989 G/AG, H/AH, & P/AP Bodies


Subject


Carpet Melting Above Muffler


Index


EXHAUST


Date

March 13, 1989


No.


11-01-89

P-1072

(C11-02-9)

FIGURE 1:

BODY CODE LEGEND

G/AG - DAYTONA H/AH - LANCER/LeBARON GTS P/AP - SHADOW/SUNDANCE

SYMPTOM/CONDITION

Exhaust system heat may scorch or melt the luggage compartment carpet in the area directly above the muffler.

NOTE: THIS CONDITION CAN BE AGGRAVATED BY ANY ENGINE MALFUNCTION THAT RAISES THE EXHAUST SYSTEM TEMPERATURES (MISFIRE, RICH CONDITION, ETC.). MAKE SURE THE ELECTRONIC FUEL INJECTION SYSTEM IS FUNCTIONING AS DESIGNED. REFER TO THE APPROPRIATE DIAGNOSTIC TEST PROCEDURE.

PARTS REQUIRED

Heat Shield Service Package PN 4549356

Consists of:

1 Heat Shield P/N 4546049
5 Self Tapping Screws P/N 6033317
5 Pal Nuts P/N 6032499
1 Template P/N 4549355

REPAIR PROCEDURE

This repair involves installation of a heat shield above the muffler.

1. Remove the spare tire and any other objects from the spare tire well before proceeding with this repair procedure.
2. With the vehicle raised on a hoist, loosen and remove the rear muffler hanger and allow the muffler to hang free.

3. Place the heat shield, P/N 4546049, above the muffler with the wide end facing the front of the vehicle. Hold the shield against the floor pan and align the right rear attachment hole with the high (convex) part of the rear rib on the vertical portion of the spare tire well. (Figure 1)

4. With assistance, push the muffler assembly as far to the right as possible. With the heat shield parallel to the floor pan, drill two pilot holes through the two most rearward attaching holes, using a .144" drill. (Figure 1)

NOTE: THESE TWO HOLES ARE THE EASIEST TO ACCESS AND WILL LOCATE THE TEMPLATE TO DRILL THE REMAINING 3 HOLES.

5. Lower the vehicle. Working in the cargo area, align the template, P/N 4549355, to the 2 previously drilled pilot holes and tape it to the floor pan. Drill the remaining 3 holes using a .144" drill bit.

6. Drive all 5 self-piercing screws, P/N 6033317, into the 5 previously drilled pilot holes from the inside of the vehicle.

7. Raise the vehicle and install the heat shield, P/N 4546049, onto the screws using the pal nuts, P/N 6032499.

8. Reinstall the muffler hanger and check for interference between the muffler and heat shield by pushing up on the muffler.


POLICY: Reimbursable within the provisions of the warranty


TIME ALLOWANCE:
Labor Operation No. 11-50-05-94 . . . . . . . . . 0.8 Hrs.


Failure Code: D1 - Missing