Hyundai Sonata LF: Intake And Exhaust System / Muffler Repair procedures

Hyundai Sonata LF 2014-2019 Service Manual / Engine Mechanical System / Intake And Exhaust System / Muffler Repair procedures

Removal and Installation
Front Muffler
1.
Disconnect the battery negative terminal.
2.
Disconnect the rear oxygen sensor connector (A).

3.
Remove the front muffler (A).
Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

4.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Center Muffler
1.
Remove the bracket(A).
2.
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)

3.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
Main Muffler
1.
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)

2.
Install in the reverse order of removal.
   
When installing, replace with new gaskets.
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, C, D, E, F) between the tail pipe (or tail trim) and the rear bumper.
[Pipe type]

[Trim type]

[Bumper-integrated trim type]

3.
Remove the catalytic converter & center muffler (A).

4.
Cut the center muffler as the instruction below.
[With dent]
A.
Cut the front dent of the muffler.

[Without dent]
A.
Cut the muffler by reffering to the front dent of A/S muffler as shown in the image below.

[A/S muffler]
A.
Cut the rear dent of the A/S 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.

5.
Install the center muffler.
(1)
Install the catalytic converter (A) and the center muffler (B) for A/S by tightening the nuts lightly, not completely.

   
When installing the muffler, replace the gasket with new one.
(2)
Put the clamp (A) between the cutting part of each pipe and tighten the clamp lightly, not completely.

(3)
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)
(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 the clamp that was tightened completely. It may cause leak to reuse the clamp that was tightened completely.

    Muffler Components and Components Location

    C..

    Engine Electrical System

    ..

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    Hyundai Sonata LF 2014-2019 Service Manual: DCT Control Module (TCM) Schematic Diagrams


    1. TCM Connector and Terminal Function 2. TCM Terminal Function Connector [A] PinDescriptionPinDescription1Clutch Actuator (Clutch Motor 1 (ODD)_Phase V)17-2Clutch actuator (Clutch Motor 2 (EVEN) Phase V)18Clutch Actuator (Clutch Motor 1 (ODD)_HALL 1)3Select Actuator (Shift Solenoid 2 (EVEN)_Ground)19Clutch Actuator (Clutch Motor 1 (ODD)_Supply)4Select Actuator (Shift Solenoid 1 (ODD) Push)20Select Actuator (Shift Solenoid 1 (ODD)_Sensor Supply)5Clutch Actuator (Clutch Motor 1 (ODD)_Phase U)21Select Actuator (Shift Solenoid 2 (EVEN)_Sensor Supply)6Clutch Actuator (Clutch Motor 2 (EVEN)_Phase U)22Select Actuator (Shift Solenoid 2 (EVEN)_Sensor Ouput)7Select Actuator (Shift Solenoid 1 (ODD)_Ground)23Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 2)8Select Actuator (Shift Solenoid 2 (EVEN)_ Pull)24Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 3)9Clutch Actuator (Clutch Motor1 (ODD)_Phase W)25Clutch Actuator (Clutch Motor 2 (EVEN)_Ground)10Clutch Actuator (Clutch Motor 2 (EVEN)_Phase W)26Select Actuator (Shift Solenoid 1 (ODD)_Sensor Output)11Select Actuator (Shift Solenoid 1 (ODD) Pull)27-12Select Actuator (Shift Solenoid 2 (EVEN) Push)28Clutch Actuator (Clutch Motor 2 (EVEN)_HALL 1)13Clutch Actuator (Clutch Motor 1 (ODD)_HALL 2)29Clutch Actuator (Clutch Motor 2 (EVEN)_Supply)14Clutch Actuator (Clutch Motor (ODD)_HALL 3)30Select Actuator (Select Solenoid 1 (ODD)_Sensor Ground)15Clutch Actuator (Clutch Motor 1 (ODD)_Ground)31Select Actuator (Select Solenoid 2 (EVEN)_Sensor Ground)16-32- Connector [B] PinDescriptionPinDescription1-35-2-36-3ON / START Input37-4Paddle Shift (Up) Switch signal38-5Inhibitor Switch "P" Input signal39-6Inhibitor Switch "R" Input signal40-7Inhibitor Switch "D" Input signal41Shift Actuator (Shift Motor 2 (EVEN) _HALL 2)8Sports mode "Down" shift42Shift Actuator (Shift Motor 2 (EVEN) _HALL 3)9Clutch Speed Sensor (EVEN) Ground43Inhibitor Switch "M" Input signal10-44CAN1 Communication Port1 High11-45CAN1 Communication Port1 Low12-46-13Shift Actuator (Shift Motor 1 (ODD) _HALL 2)47-14Shift Actuator (Shift Motor 1 (ODD) _HALL 3)48Flex ray High (BP)15-49Input Speed Supply 1 (ODD)16-50Input Speed Signal 1 (ODD)17Battery Power Low VBD 51-18Paddle Shift Down signal52-19Shift Lever Select Switch53-20Inhibitor Switch "N" Input signal54Shift Actuator (Shift Motor 2 (EVEN) _Supply)21Sports mode "Up" shift55Shift Actuator (Shift Motor 2 (EVEN) _HALL 1)22-56Shift Actuator (Shift Motor 2 (EVEN) _Sensor Ground)23Input Speed Supply 2 (EVEN)57Power Ground 1 for High Current Modules245V spare supply output58Power Ground 2 for High Current Modules25-59Shift Actuator (Shift Motor 2 (EVEN)_Phase W)26Shift Solenoid 1 Position Sensor Output60Shift Actuator (Shift Motor 1 (ODD)_Phase W)27Select Actuator (Shift Motor 1 (ODD)_HALL 1)61 Power Ground 3 for High Current Modules28Select Actuator (Shift Motor 1 (ODD)_Sensor Ground)62-29-63Shift Actuator (Shift Motor 2 (EVEN)_Phase V)30CAN2 Communication Port2 High64Shift Actuator (Shift Motor 1 (ODD)_Phase V)31CAN2 Communication Port2 Low65Motor Supply Voltage 1 from Direct Battery32-66Motor Supply Voltage 2 from Direct Battery33-67Shift Actuator (Shift Motor 2 (EVEN)_Phase U)34Flex ray bus, BM68Shift Actuator (Shift Motor 1 (ODD)_Phase U) 3...

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