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

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification
• Exhaust flange gasket × 2 — Use OEM specification
• Exhaust clamp (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and allow exhaust system to cool completely (minimum 2 hours after operation).
2. Engage parking brake and place wheel chocks behind rear wheels.
3. Raise vehicle using floor jack at designated lift points and support securely with jack stands under frame rails.
4. Apply penetrating oil to all exhaust flange bolts and clamp hardware. Allow 15 minutes to penetrate.
5. Visually inspect exhaust system for excessive rust or damage that may complicate removal.

Procedure

1. 1

   Access resonator from underneath
   Position yourself under the vehicle with adequate lighting. Locate the resonator assembly between the catalytic converter and rear muffler, approximately midway along the exhaust system. Identify the forward flange connection, rear clamp connection, and rubber exhaust hangers supporting the resonator.
2. 2

   Support exhaust system
   Place a floor jack or exhaust support stand under the muffler section behind the resonator to prevent the rear exhaust from dropping when disconnected. Adjust height to maintain alignment with minimal tension on connections.
3. 3

   Remove forward flange connection
   Using a 14mm socket, remove the two bolts securing the forward flange connection between the resonator and front exhaust pipe. Work bolts back and forth if corroded. Once bolts are removed, separate the flange connection carefully and remove the old gasket. Inspect flange faces for damage or excessive corrosion.
   ⚠Exhaust flange bolts may be heavily corroded. Apply additional penetrating oil and allow time to soak if bolts are seized.
4. 4

   Loosen rear exhaust clamp
   Locate the band clamp connecting the resonator outlet to the muffler inlet pipe. Using a 14mm socket, loosen the clamp nut completely but do not remove the clamp yet. If the clamp is severely corroded, plan to replace it with a new unit.
5. 5

   Disconnect exhaust hangers
   Identify the rubber exhaust hangers supporting the resonator assembly. Using a twisting motion, disconnect each hanger from its mounting bracket. A rubber mallet may help dislodge stubborn hangers. Work from front to rear, keeping tension on the exhaust support to prevent sudden drops.
6. 6

   Remove resonator assembly
   With all connections loosened and hangers disconnected, slide the resonator rearward to separate it from the clamp connection, then lower and remove the assembly from the vehicle. Inspect all connection points and hangers on the vehicle for damage or excessive wear.
7. 7

   Clean mating surfaces
   Using a wire brush, thoroughly clean the forward flange face on the front exhaust pipe and the slip-fit connection on the muffler inlet. Remove all carbon deposits, old gasket material, and corrosion to ensure proper sealing of the new resonator.
8. 8

   Install new resonator
   Position the new resonator assembly under the vehicle. Install new exhaust flange gasket on the forward connection. Align the resonator inlet flange with the front pipe flange and start both flange bolts finger-tight. Slide the resonator outlet into the muffler inlet slip connection, ensuring proper depth of engagement (typically 2-3 inches).
9. 9

   Reconnect exhaust hangers
   Reconnect all rubber exhaust hangers to their mounting brackets, working from front to rear. Ensure hangers are fully seated and resonator is properly aligned with no binding or excessive angle at connections. Adjust exhaust support jack as needed to maintain alignment.
10. 10

    Tighten flange bolts
    Using a torque wrench and 14mm socket, tighten the forward flange bolts in a cross pattern to the specified torque. Verify both bolts are evenly tightened and flange connection is seated properly with no gaps.
    Torque spec

    Flange Bolts45 Nm (33 lb-ft)
11. 11

    Tighten exhaust clamp
    Position the band clamp (new or existing) over the slip-fit connection between resonator and muffler. Ensure clamp is centered over the joint. Using a torque wrench and 14mm socket, tighten the clamp nut to the specified torque. Verify the connection is secure with no gaps or misalignment.
    Torque spec

    Exhaust Clamps55 Nm (41 lb-ft)
12. 12

    Final alignment check
    Remove the exhaust support jack. Visually inspect the entire exhaust system to ensure proper alignment with adequate clearance from body, frame, fuel lines, and brake lines. Check that all hangers are properly engaged and exhaust components hang naturally without binding or excessive tension.

Reassembly

1. Ensure all exhaust hangers are fully seated and supporting the system properly.
2. Verify adequate clearance between exhaust components and vehicle underbody, fuel lines, and brake lines.
3. Double-check that all flange bolts and clamps are tightened to specification.

Verification

• Lower vehicle from jack stands and remove wheel chocks.
• Start engine and listen for exhaust leaks at flange and clamp connections. A hissing sound indicates a leak requiring re-torquing or gasket replacement.
• With engine running, visually inspect all connections for signs of exhaust gas escape.
• Perform a test drive and listen for any abnormal exhaust noise, rattles, or resonance issues.
• After test drive, re-inspect all connections while exhaust is warm (but not hot) for any signs of leakage or loosening.

More procedures for this vehicle