Replacement procedure of center muffler using clamp

Under warranty: Replace the center muffler assembly.

Out of warranty: It is available to replace the center muffler as the procedure below.

1. Check that the clamping part of the center muffler assembly is damaged or deformed. If the muffler is too corroded to clamp, replace the center muffler assembly.
   Fig 1: Checking Clamping Part Of Center Muffler Assembly

   Courtesy of HYUNDAI MOTOR AMERICA
2. Record the gap (A, B, C, D, E, F) between the tail pipe (or tail trim) and the rear bumper.

   [Pipe type] 

   Fig 2: Checking Gap Between Tail Pipe (Or Tail Trim) And Rear Bumper - Pipe Type

   Courtesy of HYUNDAI MOTOR AMERICA

   [Trim tvpe] 

   Fig 3: Checking Gap Between Tail Pipe (Or Tail Trim) And Rear Bumper - Trim Type

   Courtesy of HYUNDAI MOTOR AMERICA

   [Bumper-integrated trim type] 

   Fig 4: Checking Gap Between Tail Pipe (Or Tail Trim) And Rear Bumper - Bumper-Integrated Trim Type

   Courtesy of HYUNDAI MOTOR AMERICA
3. Remove the catalytic converter & center muffler (A).
   Fig 5: Locating Catalytic Converter And Center Muffler

   Courtesy of HYUNDAI MOTOR AMERICA
4. Cut the center muffler as the instruction below.

   [With dent] 

   • Cut the front dent of the muffler.
   Fig 6: Cutting Points On Center Muffler - With Dent

   Courtesy of HYUNDAI MOTOR AMERICA

   [A/S muffler] 

   • Cut the rear dent of the A/S muffler.
   Fig 7: Rear And Front Dent Cutting Mark On A/S Muffler

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   NOTE:

   • To prevent a leak, remove the rust on the clamping part or the burr on the cutting part.
   • Cut the pipe vertically.

   Information 

   • Pipe cutter available to cut the pipe vertically.
     Fig 8: Pipe Cutter

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   • Use a hacksaw as the procedure below, if a pipe cutter is unavailable.
   1. Mark the cutting position to cut the pipe vertically.
      Fig 9: Cutting Mark On Pipe

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   2. Cut the pipe along the marking line by using hacksaw.
      Fig 10: Cutting Pipe Using Hacksaw

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5. Install the center muffler.
   1. Install the catalytic converter (A) and the center muffler (B) for A/S by tightening the nuts lightly, not completely.
      Fig 11: Locating Catalytic Converter And Center Muffler

      Courtesy of HYUNDAI MOTOR AMERICA
      NOTE: When installing the muffler, replace the gasket with new one.
   2. Put the clamp (A) between the cutting part of each pipe and tighten the clamp lightly, not completely.
      Fig 12: Locating Pipe Clamp

      Courtesy of HYUNDAI MOTOR AMERICA
   3. Tighten the catalytic converter and the center muffler with specified torque.

      Tightening torque: 

      39.2~58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9~43.4 lb-ft)

   4. Compare the gap between the tail pipe (or tail trim) and the rear bumper with the record measured before removing the center muffler assembly.
      NOTE: If the tail pipe is installed differently compared to the initial position, the bumper might be damaged by the pipe heat or interfere between the tail pipe and the rear bumper.
   5. Do not tighten the clamp at a time. Tighten the clamp nuts to the specified torque, by turns.

      T

      17.6~23.5 N.m (1.8 ~ 2.4 kgf.m, 13.0~17.4lb-ft)

      Fig 13: Locating Clamp Nuts

      Courtesy of HYUNDAI MOTOR AMERICA
      NOTE: Do not reuse the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.