How to Replace a Catalytic Converter on a KIA Sedona

by Jody L. Campbell

The Kia Sedona has a complex exhaust system comprising two manifold converters, a front dual-chambered exhaust pipe, the catalytic converter, two mufflers and a resonated tailpipe. If the catalytic converter gets clogged or breaks down internally, it can be replaced without having to replace any other components.

Step 1

Place the Sedona on a car lift and bring the vehicle all the way up on the lift.

Step 2

Put on the cutting glasses and light the oxyacetylene torch. Cut the two bolts on the front converter flange with the torch. Cut the bolts flush to the flange on the converter side.

Step 3

Cut the two bolts on the rear converter flange in the same manner.

Step 4

Shut off the torch and switch the cutting glasses to safety glasses. Put on the safety gloves.

Step 5

Knock out the remainder of the bolts on the front flange connection using the hammer and a long-stemmed punch. Knock out the remainder of the bolts on the rear converter flange. Allow the converter to cool down.

Step 6

Remove the catalytic converter hangers from the rubber exhaust hangers and remove the converter.

Step 7

Clean the flange connections of the front pipe and the front muffler that the converter attaches to using the angled die grinder and a coarse reconditioning disc.

Step 8

Install the new converter and gaskets. Place the converter hanger into the rubber exhaust hangers first to hold it up, insert the gaskets between the flanges and place the bolts through the flange holes to support the converter. Use a flat washer against the bolt head on one side and the lock washer and nut on the other side.

Step 9

Tighten the bolts and nuts with the impact gun, swivel and a socket while holding the bolt heads with a hand wrench.

Step 10

Remove the debris below the Sedona and lower it down to the floor.

Step 11

Start up the engine and relift the Sedona to check for exhaust leaks at the front or rear flange connections.

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