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

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

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4. Remove the LH floor under cover (A).
   Fig 4: Removing LH Floor Under Cover

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5. Remove the bracket (A).
   Fig 5: Removing Bracket

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6. Detach the rubber hanger (A) from the center muffler.
7. Remove the catalytic converter & center muffler (B).
   Fig 6: Detaching Rubber Hanger From Center Muffler

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

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   [Replacement muffler] 

   • Cut the rear groove of the replacement muffler.
   Fig 8: Cutting Rear Groove 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

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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 10: Marking Pipe Cutting Position

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   2. Cut the pipe along the marking line by using hacksaw.
      Fig 11: Cutting Pipe Along Marking Line

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9. 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: Installing 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

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   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

   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.
10. Install the bracket (A).
    Fig 15: Installing Bracket

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11. Install LH floor under cover (A).
    Fig 16: Installing LH Floor Under Cover

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12. Install RH floor under cover (A).
    Fig 17: Installing RH Floor Under Cover

    Courtesy of KIA MOTORS AMERICA, INC.