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

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers × 2 — Replace if torn or deteriorated

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and apply parking brake
3. Place wheel chocks at front wheels
4. Raise rear of vehicle using floor jack at designated rear jacking points
5. Support vehicle securely on jack stands rated for vehicle weight (minimum 3,000 lbs per stand)
6. Apply penetrating oil to all exhaust flange bolts and hanger bolts, allow to soak 15-30 minutes

Procedure

1. 1

   Inspect exhaust system
   Visually inspect the tail pipe, mid-pipe connection, and rubber hangers for damage or excessive corrosion. Document the routing of the tail pipe and positions of hangers for proper reinstallation.
2. 2

   Remove rear hanger connections
   Locate the rubber exhaust hangers supporting the tail pipe assembly (typically two hangers near the rear axle). Use a prying tool or pull the tail pipe downward to disengage the hangers from their mounting brackets. Note the orientation of hangers for reassembly.
   Torque spec

   Hanger Bolts20 Nm (15 lb-ft)
3. 3

   Remove flange connection bolts
   Locate the flange connection between the tail pipe and mid-pipe (typically located near the rear axle area). Using a 14mm or 17mm socket, remove the two or three flange bolts connecting the tail pipe to the upstream exhaust section. Support the tail pipe weight as you remove the final bolt to prevent it from dropping.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
4. 4

   Remove tail pipe assembly
   With all fasteners removed and hangers disconnected, carefully lower the tail pipe assembly away from the vehicle. Maneuver it around the rear suspension components and spare tire (if applicable) to remove completely from under the vehicle.
5. 5

   Clean flange mating surfaces
   Use a wire brush to thoroughly clean the flange surface on the mid-pipe where the tail pipe connects. Remove all old gasket material, carbon deposits, and corrosion to ensure a proper seal with the new gasket. Inspect flange for cracks or damage.
6. 6

   Prepare new tail pipe
   Remove protective coating from new tail pipe flange. Apply a thin layer of anti-seize compound to the threads of the flange bolts. Position the new exhaust flange gasket onto the mid-pipe flange, ensuring proper orientation with bolt holes aligned.
7. 7

   Install tail pipe assembly
   Lift the new tail pipe assembly into position, aligning the flange with the mid-pipe connection. Loosely start all flange bolts by hand before tightening any of them. Ensure the tail pipe is positioned to allow proper engagement with rubber hangers.
8. 8

   Torque flange bolts
   Tighten the exhaust flange bolts in a cross-pattern to ensure even loading of the gasket. Torque to specification using a calibrated torque wrench. Do not exceed specified torque as this can damage the flange or gasket.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
9. 9

   Install exhaust hangers
   Pull the tail pipe upward to align the hanger mounting points with the rubber isolators. Press or pry the rubber hangers onto their mounting brackets, ensuring they are fully seated. Verify the tail pipe has adequate clearance from the rear axle, fuel tank, and body panels (minimum 1 inch clearance recommended).
10. 10

    Final inspection and clearance check
    Visually verify all connections are secure and all fasteners are installed. Check that the tail pipe tip is positioned correctly relative to the rear bumper cutout. Manually push and pull on the tail pipe to verify hangers are properly engaged and there is no excessive movement or contact with chassis components.

Reassembly

1. Ensure all flange bolts are torqued to specification with anti-seize applied
2. Verify rubber hangers are fully seated and not torn or damaged
3. Confirm minimum 1 inch clearance between tail pipe and all chassis/suspension components
4. Lower vehicle from jack stands in reverse order of raising

Verification

• Start engine and allow to idle while listening for exhaust leaks at the flange connection (hissing or ticking sounds indicate leak)
• With engine running, visually inspect flange connection for escaping exhaust gases
• Perform a test drive and listen for abnormal exhaust noise, rattling, or vibration
• After test drive, re-check flange bolts are still torqued properly (may need slight adjustment after heat cycle)
• Verify tail pipe tip remains centered in bumper cutout and does not contact bumper under acceleration or deceleration

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