Replacement Procedure Of Center Muffler And Catalytic Converter 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 If Clamping Part Of The Center Muffler And Catalytic Converter Assembly Is Damaged Or Deformed

   Courtesy of KIA MOTORS AMERICA, INC.
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: Identifying Gap Between The Tail Pipe And The Rear Bumper (1 Of 3)

   Courtesy of KIA MOTORS AMERICA, INC.

   [Trim type] 

   Fig 3: Identifying Gap Between The Tail Pipe And The Rear Bumper (2 Of 3)

   Courtesy of KIA MOTORS AMERICA, INC.

   [Bumper-integrated trim type] 

   Fig 4: Identifying Gap Between The Tail Pipe And The Rear Bumper (3 Of 3)

   Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the catalytic converter and center muffler (A).
   Fig 5: Identifying Catalytic Converter And Center Muffler

   Courtesy of KIA MOTORS AMERICA, INC.
4. Cut the center muffler as the instruction below.

   [With groove] 

   1. Cut the front groove of the muffler.
      Fig 6: Identifying Muffler Dents

      Courtesy of KIA MOTORS AMERICA, INC.

   [Without groove] 

   1. Cut the muffler by referring to the front groove of replacement muffler as shown in the illustration below.
      Fig 7: Identifying Muffler Cutting Location

      Courtesy of KIA MOTORS AMERICA, INC.

   [Replacement muffler] 

   1. Cut the rear groove of the replacement muffler.
      Fig 8: Identifying Rear Dent Of The Muffler

      Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:

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

      • Pipe cutter available to cut the pipe vertically.
        Fig 9: Identifying Pipe Cutter

        Courtesy of KIA MOTORS AMERICA, INC.
      • Use a hacksaw as the procedure below, if a pipe cutter is unavailable.

      1. Mark the cutting position to cut the pipe vertically.
         Fig 10: Marking The Cutting Position To Cut The Pipe Vertically

         Courtesy of KIA MOTORS AMERICA, INC.
      2. Cut the pipe along the marking line by using hacksaw.
         Fig 11: Cutting The Pipe Along The Marking Line

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5. Install the center muffler.
   1. Install the catalytic converter (A) and the center muffler (B) for replacement by tightening the nuts lightly, not completely.
      Fig 12: Identifying Catalytic Converter & Center Muffler

      Courtesy of KIA MOTORS AMERICA, INC.
      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 13: Identifying Clamp

      Courtesy of KIA MOTORS AMERICA, INC.
   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.

      Tightening torque : 

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

      Fig 14: Identifying Clamp

      Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:

      Do not reuse the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.