Kia Sportage: Intake And Exhaust System / Muffler Repair procedures

Kia Sportage QL (2015-2025) Service Manual / Engine Mechanical System / Intake And Exhaust System / Muffler Repair procedures

Removal and Installation

Front Muffler

1.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

2.	Detach the rubber hanger (A) from the front muffler.

Remove the front muffler (B).

Tightening torque :

39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)

When installing, replace with new gaskets.

4.	Install in the reverse order of removal.

Center Muffler

1.	Detach the rubber hanger (A) from the center muffler.

Remove the catalytic converter and the center muffler (B).

Tightening torque :

39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)

When installing, replace with new gaskets.

3.	Install in the reverse order of removal.

Rear Muffler

1.	Detach the rubber hangers (A) from the main muffler.

Remove the main muffler (B).

Tightening torque :

39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)

[Single tail type]

[Dual tail type]

When installing, replace with new gaskets.

3.	Install in the reverse order of removal.

Replacement procedure of center muffler using clamp

Under warranty : Replace the center muffler assembly.

Out of warranty : It is available to replace the center muffler as the procedure below.

1.	Check that the clamping part of the center muffler assembly is damaged or deformed. If the muffler is too corroded to clamp, replace the center muffler assembly.

2.	Record the gap (A,B) between the tail pipe (or tail trim) and the rear bumper. [Pipe type] [Trim type]

3.	Detach the rubber hanger (A) from the center muffler.

4.	Remove the catalytic converter & center muffler (B).

Cut the center muffler as the instruction below.

- Cut the front groove of the muffler.

[Replacement muffler]

-Cut the rear groove of the replacement muffler.

•	To prevent a leak, remove the rust on the clamping part or the burr on the cutting part.

•	Cut the pipe vertically.

•	Pipe cutter available to cut the pipe vertically .

•	Use a hacksaw as the procedure below, if a pipe cutter is unavailable.

1)	Mark the cutting position to cut the pipe vertically.

2)	Cut the pipe along the marking line by using hacksaw.

Install the center muffler.

(1)	Install the rubber hanger (A).

(2)

Install the catalytic converter (B) and the center muffler (C) for replacement by tightening the nuts lightly, not completely.

When installing the muffler, replace the gasket with new one.

(3)	Put the clamp (A) between the cutting part of each pipe and tighten the clamp lightly, not completely.

(4)

Tighten the catalytic converter and the center muffler with specified torque.

Tightening torque :

39.2~58.8 N·m (4.0 - 6.0 kgf·m, 28.9~43.4 lb·ft)

(5)

Compare the gap between the tail pipe(or tail trim) and the rear bumper with the record measured before removing the center muffler assembly.

If the tail pipe is installed differently compared to the initial position, the bumper might be damaged by the pipe heat or interfere between the tail pipe and the rear bumper.

(6)

Do not tighten the clamp at a time. Tighten the clamp nuts to the specified torque, by turns.

Tightening torque :

17.6~23.5 N·m (1.8 - 2.4 kgf·m, 13.0~17.4lb·ft)

Do not reuse the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.

Muffler Components and components location

Components 1. Front muffler 2. Catalytic converter & Center muffler assembly 3. Rear muffler [Single tail type] 4. Rear muffler [Dual tail type ...

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