Hyundai Tucson Repair Manual: MUFFLER

Components and Component Location

COMPONENTS

1. Front Muffler
2. Catalytic Converter and Center Muffler
3. Main Muffler

4. Gasket
5. Support

Repair Procedures

Removal and Installation

Front Muffler

1
Disconnect the heated oxygen sensor connector (A), then remove the sensor.
2
Remove the rear engine under cover (A).
3
Disconnect the rubber hanger (A) from the front muffler.
4
Remove the front muffler (B).
Tightening torque: 39.2 ~ 59 N·m
NOTE
- When installing, replace the gaskets with new ones.
5
To install, perform the removal procedure in reverse order.
6
Remove the heated oxygen sensor. (Refer to Fuel System/Engine Control - "Heated Oxygen Sensor (HO2S)")
7
Remove the catalytic converter and center muffler assembly (A).
Tightening torque: 39.2 ~ 59 N·m
NOTE
- When installing, replace the gaskets with new ones.
8
To install, perform the removal procedure in reverse order.
9
Remove the main muffler (A).
Tightening torque: 39.2 ~ 59 N·m
NOTE
- When installing, replace the gaskets with new ones.
10
To install, perform the removal procedure in reverse order.
11
Make sure the center muffler clamp is not damaged or deformed. If the muffler is too corroded to be loosened, replace the center muffler assembly.
12
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]
13
Remove the catalytic converter and center muffler (A).
14
Cut the center muffler as described below. [With Impact]
- Cut the front muffler flange.
[Non-Impact]
- Cut the muffler at the front muffler flange (A/S) as shown in the illustration below.
[A/S Muffler]
- Cut the rear muffler flange (A/S).
NOTE
- To prevent leaks, remove rust from the clamp part or burrs from the cut area.
- Cut the pipe vertically.
NOTE
- The pipe cutter is designed for vertical cutting of the pipe.
- If a pipe cutter is not available, use a hacksaw as described below.
1. Mark the cutting line on the pipe vertically.
2. Cut the pipe along the marked line using a hacksaw.
15
Install the center muffler.
1. Install the catalytic converter (A) and center muffler (B) on the (A/S) and loosely tighten the nuts, but do not fully tighten them.
  NOTE
  - When installing the muffler, replace the gasket with a new one.
2. Place pliers (A) between the cut ends of each pipe and lightly tighten the pliers, but do not fully tighten them.
3. Tighten the catalytic converter and center muffler to the specified torque.
  Tightening torque: 39.2~59 N·m
4. Compare the clearance between the exhaust pipe (or tailgate) and the rear bumper with the measurement taken before removing the center muffler.
  NOTE
  - If the exhaust pipe is installed in a different position from the original, the bumper may be damaged by pipe heat or interference may occur between the exhaust pipe and the rear bumper.
5. Do not fully tighten the clamp at this time. Tighten the clamp nuts to the specified torque, in turns.
  Tightening torque: 17.6~24 N·m
  NOTE
  - Do not reuse a clamp that has been fully tightened. Reusing a fully tightened clamp may cause leaks.

Center Muffler, Main Muffler, Center Muffler with Clamp Replacement Procedure. Under warranty: Replace the center muffler. Out of warranty: The center muffler may be replaced using the procedure described below.