This bulletin provides information related to a reported “no-start” condition, on some Sportage models produced in October 2004, after they’re parked overnight in areas where the temperature is below freezing. These vehicles may experience a no-start condition in very cold climates because of an exhaust system restriction due to ice accumulation in the low area of the muffler pipe assembly.

Follow these guidelines to drill the proper size and position hole in the pipe to allow the condensation/water to drain from the muffler pipe assembly to prevent ice buildup and freezing.

Service Procedure:

1. Raise and properly support the vehicle.

2. Remove the four center muffler pipe retaining nuts and remove the pipe and muffler from the vehicle.

3. Inspect the exhaust pipe and muffler for ice accumulation.

Note: If the exhaust pipe is blocked by ice, remove the ice prior to drilling a drain hole in the main muffler pipe.

4. Measure and drill a 3mm hole on the bottom side of the main muffler pipe.

Note: Muffler pipes may be oval or round in configuration; the distance measurement is the same for both types.

5. Install the muffler assembly and intermediate pipe as required using new exhaust pipe gaskets.
• Tighten the exhaust system retaining nuts to 30-44 lbs-ft. (40-60 Nm).

6. The repair is complete; lower the vehicle from the service lift.

Courtesy of Mitchell 1.