Replacement Procedure Of Catalytic Converter & Center Muffler Assembly Using Clamp

Under warranty: Replace the catalytic converter & center muffler assembly.

Out of warranty: Catalytic converters and center muffler assemblies can be replaced in the following procedure:

1. Check if the clamping part of the catalytic converter & center muffler assembly is damaged or deformed.

   If the muffler is too corroded to clamp, replace the catalytic converter & center muffler assembly.

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2. Record the gap (A, B) between the tail pipe and the rear bumper.

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3. Remove the catalytic converter & center muffler assembly
   1. Remove the rubber hanger (A).
   2. Remove the catalytic converter & center muffler assembly (B) after removing the nuts.

      Tightening torque: 

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

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4. Cut the catalytic converter & center muffler assembly as in the instruction below.
   • Cut the front groove of the muffler.

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   [Replacement muffler] 

   • Cut the rear groove of the replacement muffler.

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   NOTE:

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

   Information 

   • Use a pipe cutter to cut the pipe vertically.

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   • If pipe cutter is unavailable, use a hacksaw as in the procedure below.
     1. Mark the cutting position to cut the pipe vertically.

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     2. Cut the pipe along the marked line by using a hacksaw.

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5. Install the center muffler.
   1. Install the catalytic converter (A) and the center muffler (B) for replacement by partially tightening the nuts.

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   2. Place the clamp (A) between the cutting part of each pipe and partially tighten the clamp.

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   3. Tighten the catalytic converter and the center muffler to the 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 measurement taken before removing the center muffler assembly.
      NOTE: If the tail pipe is installed differently from the initial position, the bumper may get damaged by the pipe heat or interference 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)

Courtesy of KIA MOTORS AMERICA, INC.