Recall - Manifold Catalytic Converter Replacement
VOLUME2
GROUP
Campaign
NUMBER
016
MODEL
Sportage
DATE
September 2000
SUBJECT:
Emissions Recall Campaign: Sportage Manifold Catalytic Converter Replacement
This bulletin provides information related to a recall for 1998 Sportage Manifold Catalytic Converter replacement. Some 1998 model year Sportages may have manifold catalytic converters that could develop cracks. If a crack occurs, noise and leakage of exhaust gas will result.
To correct this potential problem, Kia is recalling all affected 1998 Sportage models to replace the manifold catalytic converter.
* NOTICE
There is no charge to the customer for this repair. Under applicable law you may not sell or otherwise deliver any affected 1998 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 label.
If sticker is present, campaign has already been done - NO ACTION IS REQUIRED.
2. If campaign completion label is not present, continue on to Repair Procedure.
!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. Position vehicle on lift, but do not raise.
CAUTION
A hot exhaust system can produce a serious burn.
2. Remove engine oil dipstick.
3. Remove flexible air intake duct and MAF sensor after loosening hose clamps (2), connector C129, and 6 mm bolt. (photo 2)
4. Loosen wire tie, disconnect front 02 sensor connector (C131).
5. Loosen bolts (4) that attach heat shield to exhaust manifold. Remove heat shield.
CAUTION
Heat shield may have sharp edges!
6. Spray penetrating oil on manifold to converter flange studs to facilitate removal of nuts. (photo 3)
7. Loosen nuts (5) that secure converter to manifold.
Note:
loosen nuts far enough so that nuts can be rotated by hand from below the vehicle later on, but do not remove.
8. Raise vehicle.
9. Spray penetrating oil on converter to front pipe flange stud nuts (3) to facilitate later removal. (photo 4)
10. Remove 8 mm bolt securing exhaust front pipe to bell housing bracket. (photo 5)
11. Disconnect rear 02 sensor (C199).
12. Loosen and remove nuts (2) securing rear converter to main silencer pipe flange. (photo 6)
Note:
If improved front pipe and converter have been installed, loosen and remove the two attaching nuts and springs at flexible joint before the converter. (photo 7)
13. Remove nuts (3) securing front pipe to converter. (photo 8)
14. Remove front pipe.
15. While supporting converter remove nuts (5) securing it to manifold. Remove converter and old gasket.
16. Check all exhaust mating surfaces, clean as required, install new gaskets.
17. Install new manifold converter to exhaust manifold, making sure the cut out in heat shield is positioned over engine support bracket bolt. (photo 9)
Reach up over manifold flange and install self-locking nuts (5) to support converter.
18. Install front pipe and catalytic converter assembly between manifold converter and silencer mounting flanges using new gaskets.
19. Install nuts (3) securing front pipe to catalytic converter and torque to 27-34 ft-lb. (photo 8)
20. Install nuts (2) on rear converter studs and torque to 27-34 ft-lb. (photo 10)
Note:
If a revised front pipe with separate rear catalytic convertor assembly is installed on vehicle, reinstall springs and attaching nuts and torque to 27-34 ft-lb. (photo 11)
21. Install and tighten 8 mm bolt securing front pipe to bell housing bracket. (photo 12)
22. Connect rear 02 sensor connector (C199).
23. Lower vehicle.
24. Tighten nuts (5) securing front converter to manifold to 16-21 ft-lbs. (photo 13)
25. Install heat shield over manifold while feeding front 02 sensor connector and lead through opening in shield.
CAUTION
Heat shield may have sharp edges!
26. Install 4 bolts securing heat shield to manifold, tighten to 12-16 ft-lbs.
27. Route front 02 sensor wiring through wire hanging bracket on back of cylinder head, connect C131 connector halves and reinstall wire tie removed in step 6.
28. Reinstall flexible air intake and MAF sensor and tighten the 2 hose clamps. Connect C129 and install and tighten 6 mm bolt. (photo 14)
29. Install engine oil dipstick.
30. Start engine, verify proper operation and no exhaust leaks.
31. Clean completion label mounting surface and apply SCO16 completion label. (photo 15)
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 1998 model year Sportages.
Parts Number Information:
Warranty Claim Information: