Kia Picanto JA: Intake And Exhaust System / Muffler

Kia Picanto (JA) 2017-{YEAR} Service & Repair Manual / Engine Mechanical System / Intake And Exhaust System / Muffler

Components and components location
Components

1. Front muffler
2. Catalytic converter & Center muffler assembly
3. Rear muffler
4. Rubber hanger
5. Gasket

Repair procedures
Removal and Installation
Front Muffler
1.
Disconnect the negative battery terminal.
2.
Disconnect the heated oxygen sensor connector (A) and then remove them from the bracket.

3.
Detach the rubber hanger (A) from the front muffler.
4.
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 reveres order of removal.
   
When installing, replace with new gaskets.
Catalytic Converter & Center Muffler Assembly
1.
Detach the rubber hanger (A) from the catalytic converter & center muffler assembly.
2.
Remove the catalytic converter & center muffler assembly (B).
Tightening torque
Nuts :
39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)
Clamp :
16.7 - 27.5 N·m (1.7 - 2.8 kgf·m, 12.3 - 20.3 lb·ft)

3.
Install in the reveres order of removal.
   
When installing, replace with new gaskets.
Rear Muffler
1.
Detach the rubber hanger (A) from the rear muffler.
2.
Remove the rear muffler (B).
Tightening torque :
16.7 - 27.5 N·m (1.7 - 2.8 kgf·m, 12.3 - 20.3 lb·ft)

3.
Install in the reveres order of removal.
   
When install the rear muffler, install the rubber hanger and then install the clamp to the specified torque.
Replacement procedure of center muffler using clamp
Under warranty : Replace the center muffler assembly.
Out of warranty : The center muffler can be replaced in the procedure below.
1.
Check if the clamping part of the center muffler assembly is damaged or deformed.
If the muffler is excessively corroded to clamp, replace the center muffler assembly.

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

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

5.
Cut the center muffler as instructed below.
- Cut the front groove of the muffler.

[Replacement muffler]
-Cut the rear groove on the replacement muffler.

   
•
To prevent leakage, remove the rust on the clamping part or the burr on the perforation.
•
Cut the pipe breadthwise.
   
•
A pipe cutter can be used to cut the pipe breadthwise.

•
Use a hacksaw in the procedure below, if a pipe cutter is unavailable.
1)
Mark the cutting position to cut the pipe breadthwise.

2)
Cut the pipe along the marked line by using a hacksaw.

6.
Install the center muffler.
(1)
Install the catalytic converter (A) by tightening the nuts lightly, not completely.
(2)
After connecting the rubber hanger (B), install the center muffler (C) by tightening the clamp lightly, not completely.

(3)
Tighten the catalytic converter and the center muffler to specified torque.
Tightening torque :
Nuts : 39.2 - 58.8 N·m (4.0 - 6.0 kgf·m, 28.9 - 43.4 lb·ft)
Clamp : 16.7 - 27.5 N·m (1.7 - 2.8 kgf·m, 12.3 - 20.3 lb·ft)
(4)
Compare the gap between the tail pipe (or tail trim) and the rear bumper with the recorded measurement taken before removing the center muffler assembly.
   
Installing the tail pipe differently from the initial position may result in damaged bumper due to pipe heat or interference 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, in turns.
Tightening torque :
17.6 - 23.5 N·m (1.8 - 2.4 kgf·m, 13.0 - 17.4lb·ft)

   
Clamps cannot be reused once tightened completely as reusing clamps that has been tightened completely may cause leakage.

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