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 For Damaged Or Deformed

   Courtesy of KIA MOTORS AMERICA, INC.
2. Record the gap (A, B) between the tail pipe (or tail trim) and the rear bumper.
   Fig 2: Recording Gap Between Tail Pipe (Or Tail Trim) And Rear Bumper

   Courtesy of KIA MOTORS AMERICA, INC.
3. Remove the RH floor under cover (A).
   Fig 3: Locating RH Floor Under Cover With Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the LH floor under cover (A).
   Fig 4: Locating LH Floor Under Cover With Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the bracket (A).
6. Detach the rubber hanger (B) from the catalytic converter & center muffler.
7. Remove the catalytic converter & center muffler (C).
   Fig 5: Locating Bracket, Rubber Hanger, Catalytic Converter Or Center Muffler With Bolts

   Courtesy of KIA MOTORS AMERICA, INC.
8. Remove the heat protector (A).
   Fig 6: Locating Heat Protector

   Courtesy of KIA MOTORS AMERICA, INC.
9. Cut the center muffler as the instruction below.
   • Cut the front groove of the muffler.
     Fig 7: Locating Front Groove Cutting Mark Of Muffler

     Courtesy of KIA MOTORS AMERICA, INC.

     [Replacement muffler] 

   • Cut the rear groove of the replacement muffler.
     Fig 8: Locating Rear Groove Cutting Mark Of Replacement 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.

   Information 

   • Pipe cutter available to cut the pipe vertically.
     Fig 9: 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: Locating Pipe Cutting Mark

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

      Courtesy of KIA MOTORS AMERICA, INC.
10. 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: Locating Catalytic Converter And 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: Locating Clamp With Nuts

       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 - 17.4 lb.ft)

       Fig 14: Locating Clamp With Nuts

       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.