This procedure covers removal and replacement of the rear section of the exhaust system on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, from the mid-pipe flange to the rear muffler and tailpipe assembly.

Warnings

Tools required

Parts

• Rear exhaust section assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust hanger rubber isolators (if damaged) × 3 — Use OEM specification

Preparation

1. Park vehicle on a level surface and apply parking brake
2. Place wheel chocks at front wheels
3. Allow exhaust system to cool completely (minimum 2 hours after engine operation)
4. Raise rear of vehicle and support securely on jack stands at manufacturer-designated lift points
5. Spray all exhaust flange bolts and hanger fasteners with penetrating oil and allow 15-30 minutes to soak

Procedure

1. 1

   Remove heat shield (if equipped)
   Locate the rear exhaust heat shield if present. Remove the heat shield mounting bolts using a 10mm socket. Set the heat shield aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Support the rear exhaust section
   Position a floor jack or suitable support under the rear muffler to support its weight during removal. This prevents the exhaust from dropping suddenly and damaging components or causing injury.
   ⚠The rear exhaust section is heavy and awkward. Use adequate support to prevent it from falling during removal.
3. 3

   Disconnect exhaust hangers
   Locate the rubber exhaust hanger isolators supporting the rear section (typically 2-3 hangers). Using a prying tool or by hand, carefully separate the exhaust hanger rods from the rubber isolators. Work from rear to front. Inspect rubber isolators for cracking or deterioration and replace if damaged.
   ℹ️Applying soapy water to rubber isolators can ease removal and installation.
4. 4

   Remove flange bolts at mid-pipe connection
   Locate the flange connection between the mid-pipe and rear exhaust section (typically at the rear axle area). Using a 14mm or 17mm socket (verify size on your specific vehicle), remove the two flange bolts connecting the sections. Support the rear section as you remove the final bolt.
   ⚠If bolts are severely corroded and break, you may need to drill out broken studs or replace the mid-pipe flange.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
5. 5

   Remove rear exhaust section
   Carefully lower the rear exhaust section from the vehicle. Maneuver it past the rear axle, suspension components, and fuel tank. Remove and discard the old flange gasket from the mid-pipe connection.
   ⚠Watch for sharp edges on the exhaust pipes and heat shields during removal.
6. 6

   Clean flange mating surfaces
   Using a wire brush, thoroughly clean the flange surface on the mid-pipe where the new rear section will connect. Remove all old gasket material, carbon deposits, and corrosion to ensure a proper seal.
   ℹ️A clean flange surface is critical to prevent exhaust leaks.
7. 7

   Position new rear exhaust section
   Install the new flange gasket onto the mid-pipe flange. Position the new rear exhaust section into place, aligning the flange holes. Support the section with a jack while aligning. Loosely start both flange bolts by hand to hold the section in position.
8. 8

   Install exhaust hangers
   Insert each exhaust hanger rod into its corresponding rubber isolator. Work from front to rear. Ensure all hangers are fully seated and the exhaust is positioned correctly with adequate clearance from the fuel tank, body, and suspension components.
   ℹ️The exhaust should hang with approximately 15-25mm clearance from all surrounding components.
9. 9

   Torque flange bolts
   Apply anti-seize compound to the threads of both flange bolts. Using a torque wrench, tighten the flange bolts in a cross pattern to the specified torque. Verify the flange connection is fully seated and gasket is compressed evenly.
   ⚠Do not apply anti-seize to the gasket surface, only to bolt threads.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
10. 10

    Reinstall heat shield
    If a heat shield was removed, position it back in place and install the mounting bolts. Torque the heat shield bolts to specification. Ensure the shield does not contact the exhaust pipe directly.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
11. 11

    Final inspection and clearance check
    Visually inspect all connections and hangers. Verify the entire exhaust system has proper clearance from the fuel tank, body panels, suspension components, and rear axle throughout its length. Gently push on the exhaust at various points to confirm adequate clearance during movement.
    ℹ️Insufficient clearance will cause rattling, vibration, and potential damage during driving.

Reassembly

1. Lower the vehicle from jack stands carefully
2. Remove wheel chocks

Verification

• Start the engine and listen for exhaust leaks at the flange connection and along the entire rear section
• Check for unusual vibrations or rattling noises at idle and during light throttle
• Visually inspect underneath the vehicle while the engine is running for any signs of exhaust leaks (visible smoke or soot)
• Take a short test drive and verify no exhaust odors enter the cabin and no unusual noises are present
• Re-inspect all connections and clearances after the test drive to ensure nothing has shifted

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