This procedure covers removal and installation of the intermediate exhaust pipe on a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine, including catalytic converter connections and oxygen sensor handling.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification
• Exhaust flange gaskets × 2 — Use OEM specification
• Exhaust mounting hardware kit × 1 — Replacement nuts and bolts as needed

Preparation

1. Ensure exhaust system is completely cool to the touch
2. Raise vehicle on lift or securely support on jack stands at all four corners
3. Spray all exhaust fasteners with penetrating oil and allow to soak for 15-30 minutes
4. Ensure adequate ventilation in work area to disperse exhaust residue dust

Procedure

1. 1

   Remove heat shields
   Locate and remove any heat shields covering the intermediate pipe area. Remove heat shield bolts and carefully lower shields away from the exhaust pipe. Note the orientation and position of shields for reinstallation.
   Torque spec

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

   Disconnect oxygen sensor electrical connector
   Locate the downstream oxygen sensor on the intermediate pipe. Press the locking tab and disconnect the electrical connector. Carefully route the wiring harness away from the work area to prevent damage.
   ⚠Do not pull on oxygen sensor wires. Always disconnect at the connector body to prevent internal wire damage.
3. 3

   Remove downstream oxygen sensor
   Using a 22mm oxygen sensor socket, carefully remove the downstream oxygen sensor from the intermediate pipe. Turn counterclockwise and remove completely. Inspect sensor condition and threads.
   ⚠Oxygen sensors are fragile. Avoid dropping or striking the sensor element.
   Torque spec

   O2 Sensor45 Nm (33 lb-ft)
4. 4

   Support intermediate pipe
   Position a jack or support stand under the intermediate pipe to support its weight once disconnected. This prevents the pipe from falling and causing injury or damage to other components.
   ⚠Exhaust pipes are heavier than they appear and can cause injury if they fall unexpectedly.
5. 5

   Disconnect front flange connection
   Remove the bolts or nuts connecting the intermediate pipe to the catalytic converter or front exhaust pipe. Use a 14mm or 17mm socket as applicable. Support the pipe as you remove the last fastener. Separate the flange connection and remove the old gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
6. 6

   Remove exhaust hanger connections
   Locate the rubber hanger mounts supporting the intermediate pipe. Use a pry bar if necessary to disconnect the pipe hangers from the rubber isolators. Note the position of each hanger for proper reinstallation.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
7. 7

   Disconnect rear flange connection
   Remove the bolts connecting the intermediate pipe to the rear exhaust section. Carefully separate the flange and remove the old gasket. Lower the intermediate pipe away from the vehicle.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
8. 8

   Clean mating surfaces
   Use a wire brush to thoroughly clean all flange mating surfaces on both the front and rear connections. Remove all old gasket material, carbon deposits, and corrosion to ensure proper sealing with new gaskets.
   ℹ️Wear eye protection when wire brushing exhaust components as carbon particles can become airborne.
9. 9

   Install new intermediate pipe
   Position new gaskets on both flange connections. Lift the new intermediate pipe into position, aligning with front catalytic converter flange first. Install front flange bolts hand-tight. Apply anti-seize compound to exhaust flange bolt threads before installation.
   Torque spec

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

    Connect rear flange and hangers
    Align the rear flange with the mating surface on the rear exhaust section. Install new gasket and insert flange bolts hand-tight. Connect all rubber hanger mounts. Ensure pipe is properly positioned and has adequate clearance from body, driveshaft, and suspension components.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Hanger Bolts20 Nm (15 lb-ft)
11. 11

    Torque all exhaust connections
    Starting with the front flange, torque all exhaust flange bolts to specification in a cross-pattern to ensure even gasket compression. Then torque hanger bolts to specification. Verify all connections are secure and flanges are fully seated.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)

    Hanger Bolts20 Nm (15 lb-ft)
12. 12

    Install oxygen sensor
    Apply a small amount of anti-seize compound to the oxygen sensor threads only, avoiding the sensor tip and element. Thread the oxygen sensor into the intermediate pipe by hand, then torque to specification using the oxygen sensor socket.
    ⚠Never apply anti-seize to oxygen sensor element. Contamination will cause sensor failure and false readings.
    Torque spec

    O2 Sensor45 Nm (33 lb-ft)
13. 13

    Reconnect oxygen sensor connector
    Route the oxygen sensor wiring properly, ensuring it does not contact hot exhaust surfaces or moving components. Connect the electrical connector firmly until it clicks into place. Verify the locking tab is fully engaged.
    ⚠Ensure oxygen sensor wiring has adequate clearance from exhaust components and will not melt during operation.
14. 14

    Reinstall heat shields
    Position heat shields in their original locations and install heat shield bolts. Torque to specification. Ensure shields do not contact or rattle against the exhaust pipe.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all exhaust connections are torqued to specification and gaskets are properly seated
2. Confirm all rubber hanger mounts are properly engaged and exhaust has proper clearance
3. Check that oxygen sensor wiring is routed away from heat sources and moving parts
4. Ensure heat shields are secure and properly positioned

Verification

• Lower vehicle and start engine. Listen for any exhaust leaks at flange connections
• Allow engine to reach operating temperature and inspect all connections for leaks or unusual sounds
• Verify no rattles or vibrations from exhaust system during idle and acceleration
• Check for proper oxygen sensor operation using a scan tool. Verify no diagnostic trouble codes are present
• Perform a test drive and verify no exhaust smell in cabin and normal exhaust sound
• After test drive, re-inspect all connections while engine is still warm for any signs of leakage

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