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Kia Sedona: Muffler Repair procedures - Intake And Exhaust System - Engine Mechanical System - Kia Sedona YP Service ManualKia Sedona: Muffler Repair procedures

Third generation YP (2014-2025) / Kia Sedona YP 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.
Disconnect the RH rear oxygen sensor (HO2S) connector (A).

3.
Disconnect the LH rear oxygen sensor (HO2S) connector (A).

4.
Remove the front muffler hanger (A) and then 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)

5.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Catalytic converter & Center Muffler Assembly
1.
Remove the hanger (A) from the catalytic converter & center muffler assembly.
2.
Remove the catalytic converter & center muffler assembly (B).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Rear Muffler
1.
Remove the hanger (A) from the rear muffler.

2.
Remove the rear muffler (A).
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Tail Muffler
1.
Remove the hanger (A) from the tail muffler.

2.
Remove the tail muffler (A).
Tightening torque :
9.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

3.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Replacement procedure of catalytic converter & center muffler assembly using clamp
Under warranty : Replace the catalytic converter & center muffler assembly.
Out of warranty : Catalytuc converters and center muffler assemblies can be replaced in the following procedure:
1.
Check if the clamping part of the catalytic converter & center muffler assembly is damaged or deformed.
If the muffler is too corroded to clamp, replace the catalytic converter & center muffler assembly.

2.
Record the gap (A) between the tail pipe and the rear bumper.

3.
Remove the hanger (A) from catalytic converter & center muffler assembly.
4.
Remove the catalytic converter & center muffler assembly (B).

5.
Cut the catalytic converter & center muffler assembly as in the instruction below.
–
Cut the front groove of the muffler.

[Replacement muffler]
–
Cut the rear groove of the replacement muffler.

   
•
To prevent leakage, remove the rust on the clamping part or the burr on the cutting part..
•
Cut the pipe vertically.
   
•
Use a pipe cutter to cut the pipe vertically.

•
If pipe cutter is unavailable, use a hacksaw as in the procedure below.
1)
Mark the cutting position to cut the pipe vertically.

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

6.
Install the center muffler.
(1)
Install the catalytic converter (A) and the center muffler (B) for replacement by partially tightening the nuts.

(2)
Place the clamp (A) between the cutting part of each pipe and partially tighten the clamp.

(3)
Tighten the catalytic converter and the center muffler to the specified torque.
Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
(4)
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.
(5)
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 clamps that have been tightened completely. Reusing clamps that have been tightened completely may cause leakage.
Muffler Components and Components Location
Components 1. Gasket2. Hanger3. Front muffler4. Catalytic converter & Center muffler assembly5. Rear muffler6. Tail muffler ...

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