Hyundai i20 Quiz
Engine Mechanical System

Muffler Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
17steps
~102min
4/5difficulty
02040608010058.843N·mlb·ft
Tightening torque found on this page
Done 0 of 17

Removal and Installation

Front Muffler
  1. Disconnect the negative battery cable.
  2. Remove the engine cover. (Refer to Engine and Transaxle - "Engine Cover")
  3. Remove the engine undercover. (Refer to Engine and Transaxle Assembly - "Engine Undercover")
  4. Disconnect (A) from the rear oxygen sensor.
  5. Remove the hanger (A).
  6. Remove the front muffler (B).

    Tightening torque: 39.2 ~ 59 N·m

  7. To install, perform the removal procedure in reverse order.
  8. Catalytic Converter Replacement Procedures Using Clamps
    1. Make sure the main muffler clamps are not damaged or deformed.
    2. Measure the clearance (A, B, C, D, E, F) between the exhaust pipe (or rear door trim) and the rear bumper. [Pipe Type]
      [Trim Type]
      [Bumper Integrated Trim Type]
    3. Cut the main muffler as shown below.
    4. Replace the catalytic converter and center muffler (A) as shown in the illustration below (refer to the clamp installation procedures).
  9. Center Muffler Including Catalytic Converter Replacement Procedures Using Pliers
    1. Make sure the main muffler clamps are not damaged or deformed.
    2. Measure the clearance (A, B, C, D, E, F) between the exhaust pipe (or rear door trim) and the rear bumper. [Pipe Type]
      [Trim Type]
      [Bumper Integrated Trim Type]
    3. Cut the main muffler as shown below.
    4. Replace the catalytic converter and center muffler (A) as shown in the illustration below (refer to the clamp installation procedures).
  10. Center Muffler Without Catalytic Converter Replacement Procedures Using Pliers
    1. Make sure the main muffler clamps are not damaged or deformed.
    2. Measure the clearance (A, B, C, D, E, F) between the exhaust pipe (or rear door trim) and the rear bumper. [Pipe Type]
      [Trim Type]
      [Bumper Integrated Trim Type]
    3. Cut the main muffler as shown below.
    4. Cut the center muffler as shown below.[With Impact]
      • Cut the muffler pipe at the marked front stopper.
      [Non-Impact]
      • Cut the A/S muffler at the front stopper as shown in the illustration below.
      [A/S Muffler]
      • Cut the marked A/S muffler at the rear stopper.
    5. Replace the center muffler (A) as shown in the illustration below (refer to the clamp installation procedures).
  11. Main Muffler Replacement Procedures with Clamp
    1. Make sure the main muffler clamps are not damaged or deformed.
    2. Measure the clearance (A, B, C, D, E, F) between the exhaust pipe (or rear door trim) and the rear bumper. [Pipe Type]
      [Trim Type]
      [Bumper Integrated Trim Type]
    3. Cut the main muffler as shown below.
    4. Replace the main muffler (A) as shown in the illustration below (refer to the clamp installation procedures).
Clamp Installation Procedures for Catalytic Converter and Center Muffler Replacement
  1. Place the clamp (A) between the cut sections of the pipe and tighten the clamp slightly, but not fully.
  2. Tighten the catalytic converter and center muffler to the specified torque.

    Tightening Torque: 40.0 ~ 60 N·m

  3. Compare the clearance between the exhaust pipe (or rear door trim) and the rear bumper with the measurement taken before removing the center muffler assembly.
  4. Do not tighten the clamp by turning it only once. Tighten the clamp nuts to the specified torque, alternating turns a specified number of times.

    Tightening Torque: 18.0 ~ 24 N·m

Clamp Installation Procedures for Main Muffler and Center Muffler Replacement
  1. Tighten the main muffler and center muffler to the specified torque.

    Tightening Torque: 40.0 ~ 60 N·m

  2. Do not tighten the clamp by turning it only once. Tighten the clamp nuts to the specified torque, alternating turns a specified number of times.

    Tightening Torque: 18.0 ~ 24 N·m

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