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 the center muffler for deformation or damage to the part where the clamp is to be mounted.

   If clamp mounting is not possible, replace with a center muffler assembly.

   Courtesy of KIA MOTORS AMERICA, INC.

2. If clamps are available, measure and record the distance between the tail trim and rear bumper (A).

   Courtesy of KIA MOTORS AMERICA, INC.

3. Separate the rubber hook (A) from the center muffler, remove the center muffler (B) after removing the nut.

   Courtesy of KIA MOTORS AMERICA, INC.

4. Cut the clamp tightening point of the center muffler.
   • Cut the front dent position of the muffler.
     1. Front dent
     2. Rear dent

     Courtesy of KIA MOTORS AMERICA, INC.

   [New Muffler] 

   • Cut the rear dent of the replacement muffler.
     1. Front dent
     2. Rear dent

     Courtesy of KIA MOTORS AMERICA, INC.

   NOTE:

   • After tightening the fixture, remove foreign objects, rust, welding spatter and cutting residue on the cutting surface to prevent leakage and welding of the cut part of the pipe.
   • The pipe is cut vertically.

   Information 

   • Use an easy-to-cut pipe cutter that is smooth and perpendicular to the cut surface.

     Courtesy of KIA MOTORS AMERICA, INC.

   • If a pipe cutter is not available, use a hacksaw as per the procedure below.
     1. Marking (A) is made around the pipe in the dent position to cut the pipe vertically.

        Courtesy of KIA MOTORS AMERICA, INC.

     2. Cut the pipe along the marking line (B) using a hacksaw (A).

        Courtesy of KIA MOTORS AMERICA, INC.

5. Install the center muffler.
   1. Install the catalytic converter (A).
   2. Attach the rubber hook (B) and attach the central muffler (C).

      Courtesy of KIA MOTORS AMERICA, INC.

      NOTE: Replace with a new gasket upon installation.
   3. Insert and temporarily secure clamps (A) between each pipe cutout.

      Courtesy of KIA MOTORS AMERICA, INC.

   4. Tighten the nuts on the catalytic converter and exhaust heat recovery device & center muffler to the specified torque.

      Tightening torque 

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

      Clamp: 16.7 - 27.5 N.m (1.7 - 2.8 kgf.m, 12.3 - 20.3 lb.ft)

   5. Before removing the center muffler, check the distance between the tailpipe (or tail trim) and the rear bumper with a measurement record and realign if there is a problem.
      NOTE: If the position of the tail pipe is different from the initial state, the bumper may be damaged due to interference, noise, and heat between the tail pipe and the rear bumper.
   6. Tighten the clamp nut several times evenly.

      Tightening torque: 

      17.7 - 24.5 N.m (1.8 - 2.5 kgf.m, 13 - 18.1 lb.ft)

      Courtesy of KIA MOTORS AMERICA, INC.

      NOTE: Do not reuse a fully tightened clamp it may have internal deformation.