Recall - Catalytic Converter Replacement

VOLUME
2

GROUP
Campaign

NUMBER
011

MODEL
Sportage

DATE
October, 1999

SUBJECT:
Emissions Recall Campaign: Sportage Catalytic Converter Replacement

This bulletin provides information related to a recall for 1995 Sportage Catalytic Converter replacement. Some 1995 model year Sportages equipped with DOHC engine may have catalytic converters that have deteriorated internally. Deteriorated converters usually result in complaints of buzzing/rattling noises. However, in extreme cases of deterioration, loss of power and/or failure of vehicle to pass a vehicle inspection for registration renewal emission test will result. To correct these potential problems, Kia is recalling all affected 1995 Sportage DOHC models to replace the catalytic converters.

* NOTICE:
^ There is no charge to the customer for this repair. Under applicable law you may not sell or otherwise deliver any affected 1995 Sportage until the catalytic converter has been replaced.
^ For California dealers, this recall is subject to the State of California Registration Renewal/Emission Recall Enforcement Program implemented in 1992. Involved vehicles must have the recall service completed before registration renewal.

INSPECTION:





1. Open hood and check for campaign completion sticker.

If sticker is present, campaign has already been done - NO ACTION IS REQUIRED.

2. If campaign completion sticker is not present, continue on to Repair Procedure.

REPAIR DESCRIPTION:





The replacement catalytic converter assembly and related parts differ somewhat from the original parts. The illustration shows the old and new converter assemblies. The new converter assembly comes in a kit which includes the front pipe, gaskets and hardware shown in the illustration.

WARNING:
Failure to follow procedures, or failure to adhere to Warnings, Cautions and Notices could result in personal injury and/or unnecessary vehicle repairs.

REPAIR PROCEDURE:

1. Raise vehicle on lift.

CAUTION:
A hot exhaust system can produce a serious burn.





2. Spray penetrating oil on front pipe to manifold flange studs and on rear catalytic converter flange to muffler studs to facilitate removal.

3. Disconnect 02 sensor connector (C131).

4. Carefully remove 02 sensor and washer from front pipe.

5. Remove 8 mm bolt securing exhaust front pipe clamp to bellhousing bracket.

6. Remove rubber hanger from rear of catalytic converter.





7. Remove (2) 10 mm nuts from rear catalytic converter to muffler flange.

8. Remove (3) 10 mm nuts securing front pipe to exhaust manifold.

Note:
It is not necessary to unbolt the front pipe from the converter.

9. Remove old front pipe and catalytic converter as an assembly from vehicle.

10. Install new catalytic converter to the existing muffler pipe with the new gasket and self locking nuts supplied in kit (torque 27-38 lb-ft).

11. Install 02 sensor and washer removed from old front pipe into new front pipe (torque 22-36 lb-ft).





12. Install new front pipe to exhaust manifold using the new gasket and self-locking nuts supplied in kit (torque 27-38 lb-ft).

13. Install 8 mm bolt in exhaust front pipe to bellhousing bracket (torque 15-20 lb-ft).

14. Install rubber hanger on catalytic converter.





15. Install springs on converter ball joint seal joint using 12mm nuts supplied in kit (torque 22-36 lb-ft).

16. Connect 02 sensor connector (C131).

17. Lower vehicle, start engine and check for exhaust leaks.





18. Install SC011 campaign completion sticker on underside of hood in location indicated.

For California Dealers:





For vehicles sold in California, a supplied Vehicle Emission Recall Proof of Correction Form must be completed and given to each owner upon completion of the recall service for owner use as proof during renewal of vehicle registration.

AFFECTED PRODUCTION RANGE:

All 1995 model year Sportage with DOHC engine.





PART NUMBER INFORMATION





WARRANTY CLAIM INFORMATION