This procedure covers the removal and installation of the exhaust tip on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Exhaust tip × 1 — Use OEM specification or aftermarket equivalent
• Clamp bolts/nuts × 2 — Usually reusable, replace if damaged

Preparation

1. Park vehicle on level ground and apply parking brake
2. Place wheel chocks at front wheels
3. Allow exhaust system to cool completely (minimum 1 hour after engine shutdown)
4. Raise rear of vehicle using jack and support securely on jack stands
5. Inspect exhaust tip connection type (clamp-style or slip-fit with band clamp)

Procedure

1. 1

   Apply penetrating oil to fasteners
   Spray penetrating oil on the clamp bolts/nuts that secure the exhaust tip to the muffler outlet pipe. Allow 10-15 minutes to penetrate if fasteners show corrosion. The tip is typically secured with a band clamp with 2 bolts/nuts at the rear of the muffler.
2. 2

   Loosen clamp fasteners
   Using a 13mm socket and ratchet, loosen the band clamp bolts/nuts that secure the exhaust tip. Do not fully remove yet. Loosen evenly to prevent binding of the clamp.
3. 3

   Remove clamp hardware
   Fully remove the clamp bolts/nuts and remove the band clamp from around the connection. Keep hardware organized for reuse if not replacing.
4. 4

   Remove exhaust tip
   Slide the exhaust tip rearward off the muffler outlet pipe. The tip may require twisting motion to break free if corroded. If stuck, apply additional penetrating oil and wait, or use gentle heat (not on chrome/polished tips). Inspect the muffler outlet pipe for damage or excessive corrosion.
5. 5

   Clean connection surfaces
   Use a wire brush to clean the outer surface of the muffler outlet pipe where the exhaust tip will slide on. Remove any rust, carbon buildup, or old gasket material. Wipe clean with a rag.
6. 6

   Prepare new exhaust tip
   Inspect the inner diameter of the new exhaust tip to ensure proper fit. Apply a thin layer of anti-seize compound to the outer surface of the muffler outlet pipe (approximately 2-3 inches from the end) to prevent future corrosion and seizing.
7. 7

   Install exhaust tip
   Slide the new exhaust tip onto the muffler outlet pipe. Ensure it is fully seated with approximately 2-3 inches of overlap. Align the tip for desired visual appearance and ensure proper clearance from bumper, hitch, and body panels.
8. 8

   Install and tighten clamp
   Position the band clamp over the connection joint, ensuring it covers the overlap area completely. Install the clamp bolts/nuts finger-tight, then tighten evenly in an alternating pattern using a torque wrench to manufacturer specification. If using OEM clamp, torque to 20 Nm (15 lb-ft). For aftermarket clamps, follow manufacturer torque specification, typically 15-20 lb-ft.

Reassembly

1. Double-check that exhaust tip has adequate clearance from all surrounding components
2. Verify band clamp is positioned correctly over the joint and tightened evenly
3. Lower vehicle from jack stands

Verification

• Start engine and check for exhaust leaks at the tip connection joint (listen for hissing or feel for escaping gases)
• Visually inspect tip alignment and clearance from rear bumper and surrounding components
• Allow engine to reach operating temperature and recheck for leaks
• Take a short test drive and verify no rattles or contact with body panels

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