Kia Picanto: Intake and Exhaust System / Muffler

Components and Component Location

Components

1. Front muffler
2. Catalytic converter and center muffler assembly
3. Rear muffler

4. Rubber Hanger
5. Gasket

Repair Procedures

Removal and Installation

Front Muffler

1
Disconnect the negative battery cable.
2
Disconnect the heated oxygen sensor connector (A), then remove it from the bracket.
3
Disconnect the rubber mount (A) from the front muffler.
4
Remove the front muffler (B).
Torque: 39.2 – 59 N·m
5
Install in the reverse order of removal.
NOTEWhen installing, replace the gaskets with new ones.
6
Disconnect the rubber hanger (A) from the catalytic converter and center muffler assembly.
7
Remove the catalytic converter and center muffler assembly (B). Tightening torque: Nuts: 39.2–59 N·m Clamp: 16.7–28 N·m
8
Install in the reverse order of removal.
NOTEWhen installing, replace the gaskets with new ones.
9
Disconnect the rubber hanger (A) from the rear muffler.
10
Remove the rear muffler (B).
Tightening torque: 16.7–28 N·m
11
Install in the reverse order of removal.
NOTEWhen installing the rear muffler, install the rubber hanger, then install the clamp to the specified torque.
12
Check the clamping portion of the center muffler assembly for damage and deformation. If the muffler is severely corroded, replace the center muffler assembly.
13
Record the clearance (A, B) between the exhaust pipe and the rear bumper.
14
Disconnect the rubber mount (A) from the center muffler.
15
Remove the catalytic converter and center muffler (B).
16
Cut the center muffler as described below. - Cut along the front groove of the muffler.
[Muffler Replacement] - Cut the rear groove on the replacement muffler.
NOTE
- To prevent leaks, remove rust from the clamping portion or burrs from the perforation.
- Cut the pipe across its width.
NOTE
- A pipe cutter can be used to cut the pipe across its width.
- If a pipe cutter is not available, use a hacksaw as described in the following procedure.
1. Mark the cutting position to cut the pipe across its width.
2. Cut the pipe along the marked line using a hacksaw.
17
Install the center muffler.
1. Install the catalytic converter (A), lightly tightening the nuts but not fully.
2. Connect the rubber hanger (B), then install the center muffler (C), lightly tightening the clamp but not fully.
3. Tighten the catalytic converter and center muffler to the specified torque. Tightening torque: Nuts: 39.2–59 N·m Clamp: 16.7–28 N·m
4. Compare the clearance between the exhaust pipe (or tail trim) and the rear bumper with the measurement recorded before removing the center muffler assembly.
  NOTEIf the exhaust pipe is installed in a different position from the original, the bumper may be damaged due to pipe overheating or interference between the exhaust pipe and the rear bumper.
5. Do not tighten the clamp all at once. Tighten the clamp nuts to the specified torque in turn.
  Torque: 17.6 – 24 N·m
  
  NOTEFully tightened clamps must not be reused, as reusing them may cause leaks.

Catalytic Converter and Center Muffler Assembly, Rear Muffler. Center Muffler Replacement Procedure Using Clamp. Under warranty: Replace the center muffler assembly. Warranty expired: The center muffler may be replaced using the procedure described below.