GROUP

NUMBER

Engine
DATE

Technical Service Bulletin

20-EM-001H
MODEL(S)

February, 2020

Elantra (AD), Elantra GT (PD)

CENTER MUFFLER ASSEMBLY REPLACEMENT

SUBJECT:

Description: Some 2018-2019MY Elantra (AD) and Elantra GT (PD) 2.0L vehicles may have a
weakened weld near where the center muffler is attached to the exhaust pipe. This condition may
cause the center exhaust pipe of the muffler to exhibit an exhaust leak and/or exhaust noise.
Follow the procedure outlined in this bulletin to replace the center muffler assembly to correct this
condition.
Applicable Vehicles: 2018-2019MY Elantra (AD) vehicles equipped with Nu 2.0L engines.
2018-2019MY Elantra GT (PD) vehicles equipped with Nu 2.0L engines.
Parts Information:
Part Name

Part Number

Application
28650-F2500

Elantra (AD) Nu 2.0L

28650-G3410

Elantra GT (PD) Nu 2.0L

28641-C8540

Use for attaching replacement
center muffler pipe to catalyst

Center Muffler
(QTY 1)
(Center muffler varies by P/N)
Clamp
(QTY 1)

Warranty Information:
MODEL

OP CODE

OPERATION

OP TIME

CAUSAL P/N

Elantra (AD)

28650F02

Center Muffler
Replacement

0.5 M/H

28650-F2500

Elantra GT (PD) 28650F02

Center Muffler
Replacement

0.5 M/H

NATURE
CODE

CAUSE
CODE

Q55

ZZ7

28650-G3410

NOTE: Normal warranty applies.

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

CENTER MUFFLER ASSEMBLY REPLACEMENT

SUBJECT:

Service Procedure:
1.

Lift the vehicle on a hoist and then refer to
the Shop Manual to remove the center
muffler (A) from the vehicle.
 Engine Mechanical  Intake And Exhaust
System  Muffler  Repair Procedures

!

CAUTION

A

Allow the exhaust to cool down
before performing any work.
2.

Locate the front dent (B) and rear dent (C) of
the center muffler pipe for cutting at point
(B).
C
Cut Point

C

B

B

3.

Cut the center muffler pipe perpendicular to
the front dent (B) cutting point.
 Retain the cut portion with the catalyst (F)
to be reused with the new center muffler.

NOTICE
Mark the
circumference of
the pipe and cut
the pipe by using
a pipe cutter (D),
a hack saw (E), or
equivalent.

Using a commercially available
tube cutter that is capable of
cutting up to 2-1/8” diameter steel
pipe is the recommended method
for the straightest cut.

D

E

F

TSB #: 20-EM-001H

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4.

CENTER MUFFLER ASSEMBLY REPLACEMENT

Debur the cut edge of the pipe at the rear
portion of the catalyst (F) using a metal file.

F

NOTICE
Do not allow any foreign material to
enter inside the catalyst pipe.

5.

Locate the front dent (H) and rear dent (G) of
the new replacement campaign center
muffler pipe for cutting at rear dent point
(G).

Cut Point

H

6.

Cut the new replacement center muffler pipe
perpendicular to the rear dent (G) cutting
point.
 Discard the short cut off portion of the
new center muffler.
 Debur the cut edge of the pipe at the front
portion of the replacement center muffler
pipe.

G

Discard this piece after cutting.

TSB #: 20-EM-001H

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CENTER MUFFLER ASSEMBLY REPLACEMENT

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Layout of the catalyst (F), shortened new replacement center muffler assembly (I), and clamp (J).

J
I

F

NOTICE
Remove any sticker labels and
protective covering tape from the
new replacement center muffler
assembly prior to installation.

7.

Reuse the front flange gasket and install the
catalyst (F), then temporarily hand tighten the
flange nuts.

F

TSB #: 20-EM-001H

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8.

CENTER MUFFLER ASSEMBLY REPLACEMENT

Install the clamp (J) to the catalyst pipe with
the clamp bolts facing horizontally.

J

9.

Reuse the rear flange gasket and install the
new replacement center muffler (I) to the
clamp (J), then temporarily hand tighten the
flange nuts.

J

I

10. Tighten the front flange mounting fasteners of
the center muffler catalyst.


Tightening torque: 49 Nm (36 lb-ft)

TSB #: 20-EM-001H

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CENTER MUFFLER ASSEMBLY REPLACEMENT

11. Tighten the rear flange mounting fasteners of
the center muffler pipe.


Tightening torque: 49 Nm (36 lb-ft)

12. After making sure that the two cut ends of the
pipes are butted together inside the clamp:
a) Slide and hold the clamp (J) towards the
catalyst (F) while initially tightening the
front clamp fastener.
b) Slide and hold the center muffler pipe (I)
towards the clamp (J) while initially
tightening the rear clamp fastener.


Final tightening torque: 22 Nm (16 lb-ft)

F

J

I

NOTICE
This clamp forms a crush type seal
to the pipes and therefore it cannot
be reused after tightening.
13. Verify repair.
 Elantra (AD): Check that there is
approximately 1 ⅞” of clearance between
the rear bumper cover inner edge and the
exhaust tip.
 Elantra GT (PD): Check that there is
approximately 3 ⅜” of clearance between
the rear bumper cover outer edge and the
exhaust tip.
 Operate the engine briefly to confirm that
there is no exhaust leak and/or exhaust
noise from the clamped pipe areas.

TSB #: 20-EM-001H

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