Engine Mechanical System

Muffler Repair Procedures

Removal and Installation

[Front Muffler]

1
Disconnect the rear oxygen sensor connector (A).
2
Remove the front muffler (A).
Tightening torque: 39.2 ~ 59 N·m
3
Install in the reverse order of removal.
NOTEWhen installing, replace the gaskets with new ones.
4
Remove the center muffler and main muffler assembly (A).
Tightening torque: 39.2 ~ 59 N·m
5
Install in the reverse order of removal.
NOTEWhen installing, replace the gaskets with new ones.
6
Make sure the clamping portion of the center muffler assembly is not damaged or deformed. If the muffler is too corroded to be clamped, replace the center muffler assembly.
7
Record the clearance (A, B, C, D, E, F) between the exhaust pipe (or tail finisher) and the rear bumper. [Pipe Type]
[Trim Type]
[Trim Type, Built into Bumper]
8
Remove the catalytic converter and center muffler (A).
9
Cut the center muffler as shown below. [With Groove]
- Cut the front muffler groove.
[Without Groove]
- Cut the muffler along the front replacement groove, as shown in the illustration below.
[Muffler Replacement]
- Cut the rear muffler groove of the replacement muffler.
NOTE
- To prevent leakage, remove rust on the clamping portion or burrs on the cut portion.
- 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 position to cut the pipe vertically.
2. Cut the pipe along the marked line with a hacksaw.
10
Install the center muffler.
1. Install the catalytic converter (A) and center muffler (B) for replacement, tightening the nuts slightly, not fully.
  
  NOTEWhen installing the muffler, replace the gasket with a new one.
2. Position the clamp (A) between the cut ends of each pipe and tighten the clamp slightly, but not fully.
3. Tighten the catalytic converter and center muffler to the specified torque.
  Torque: 39.2 – 59 N·m
4. Compare the clearance between the tail pipe (or tail finisher) and the rear bumper with the measurements recorded before removing the center muffler assembly.
  NOTEIf the exhaust pipe is installed differently from the original position, the bumper may be damaged, the pipe may overheat, or the tail pipe may interfere with the rear bumper.
5. Do not tighten the clamp all at once. Tighten the clamp nuts to the specified torque, alternating evenly.
Torque: 17.6 – 24 N·m

NOTEDo not reuse a fully tightened clamp. It may cause leakage.

[Center and Rear Muffler] Center Muffler Replacement Procedure Using Clamp Under warranty: Replace the center muffler assembly. Warranty not applicable: The center muffler can be replaced according to the procedure below.