Hyundai Sonata LF Quiz
Engine Mechanical System

Muffler Repair Procedures

In this manual: Engine Mechanical System
General Information — 9Engine Mechanical System — 90Engine Electrical System — 58Emission Control System — 24Engine Control System/Fuel System — 114Drive Shaft and Axle — 15Suspension System — 35Steering — 19Restraints — 50Brake System — 54Body (Interior and Exterior) — 213Body Electrical System — 241Heating, Ventilation, and Air Conditioning — 56DCT (Dual Clutch Transmission) System — 52
14steps
~84min
3/5difficulty
02040608010058.843N·mlb·ft
Tightening torque found on this page
Done 0 of 14

Removal and Installation

Front Muffler
  1. Disconnect the negative battery cable.
  2. Disconnect the rear oxygen sensor connector (A).
  3. Remove the front muffler (A).

    Tightening torque: 39.2 ~ 59 N·m

  4. Install in the reverse order of removal.
    When installing, replace the gaskets with new ones.
  5. Remove the bracket (A).
  6. Remove the catalytic converter and center muffler (B).

    Tightening torque: 39.2 ~ 59 N·m

  7. Install in the reverse order of removal.
    When installing, replace the gaskets with new ones.
  8. Remove the catalytic converter and center muffler (B).

    Tightening torque: 39.2 ~ 59 N·m

  9. Install in the reverse order of removal.
    When installing, replace the gaskets with new ones.
  10. Make sure the clamping part of the center muffler is not damaged or deformed. If the muffler is too corroded to be clamped, replace the center muffler assembly.
  11. Record the clearance (A, B, C, D, E, F) between the tailpipe (or tail trim) and the rear bumper. [Pipe Type]
    [Trim Type]
    [Trim Type, Built into Bumper]
  12. Remove the catalytic converter and center muffler (A).
  13. Cut the center muffler as described below. [With Dent]
    A. Cut out the front dent of the muffler.
    [Without Dent]
    A. Cut the muffler using the front dent of the A/S muffler as a reference, as shown in the illustration below.
    [A/S Muffler]
    A. Cut out the rear dent of the A/S muffler.
    • To prevent leaks, remove rust from the clamping part or burrs from the cutting part.
    • Cut the pipe vertically.
    • 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.
  14. Install the center muffler.
    1. Install the catalytic converter (A) and the center muffler (B) for the A/S muffler, loosely tightening the nuts but not fully.
      When 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 loosely, 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 tailpipe (or tail trim) and the rear bumper with the measurements recorded before removing the center muffler assembly.
      If the tailpipe is installed in a position different from the original, the bumper may be damaged by pipe heat or interfere between the tailpipe 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
      Do not reuse a fully tightened clamp. Reusing a fully tightened clamp may cause leaks.
Center Muffler / Main Muffler: Center Muffler Replacement Procedure Using Clamp. Under Warranty: Replace the center muffler assembly. Warranty Expired: The center muffler can be replaced as described below.

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