This procedure covers the removal and replacement of the rear exhaust pipe section on a 2015 Kia Forte 1.8L I4, including disconnecting flanges, hangers, and heat shields.

Warnings

Tools required

Parts

• Rear exhaust pipe section × 1 — Use OEM specification
• Exhaust flange gasket × 1 — Use OEM specification
• Exhaust rubber hangers (if damaged) × 2 — Use OEM specification

Preparation

1. Ensure the exhaust system is completely cool to the touch
2. Park the vehicle on a level, solid surface and engage the parking brake
3. Place wheel chocks behind the front wheels
4. Raise the rear of the vehicle using a floor jack at the designated jacking points
5. Support the vehicle securely with jack stands placed at the rear subframe or axle supports
6. Spray all exhaust flange bolts, hanger bolts, and heat shield bolts with penetrating oil and allow 15-20 minutes soak time

Procedure

1. 1

   Remove heat shield (if equipped)
   Locate the heat shield covering the rear exhaust section. Using a 14mm socket, remove the heat shield mounting bolts. Carefully lower and remove the heat shield from the exhaust system. Inspect the heat shield for damage and replace if severely corroded.
   Torque spec

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

   Disconnect oxygen sensor connector (if applicable)
   Locate the rear oxygen sensor electrical connector near the rear exhaust section. Press the locking tab and disconnect the electrical connector. Secure the wiring harness away from the work area to prevent damage.
3. 3

   Remove rear exhaust hangers
   Locate the rubber exhaust hangers supporting the rear exhaust section. Using a 14mm wrench, remove the hanger bolts securing the hangers to the vehicle body. If the rubber hangers are intact and you wish to reuse them, carefully pry the exhaust pipe loops from the rubber hangers using a pry bar or by lubricating with soapy water.
   Torque spec

   Hanger Bolts19 Nm (14 lb-ft)
4. 4

   Disconnect rear exhaust flange
   Locate the flange connection between the rear exhaust section and the muffler or tailpipe. Using two 17mm wrenches (one to hold the nut, one for the bolt), remove the exhaust flange bolts. There are typically 2 bolts at this connection. Separate the flange connection and note the position of the gasket for replacement.
   Torque spec

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

   Disconnect front exhaust flange
   Locate the flange connection between the rear exhaust section and the center or mid-pipe section. Using two 17mm wrenches, remove the exhaust flange bolts at this connection. Gently separate the flanges. If the connection is seized, use a rubber mallet to tap around the flange joint to break the seal.
   ⚠Do not pry aggressively between flanges as this may damage the sealing surfaces. Use penetrating oil and gentle tapping instead.
   Torque spec

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

   Remove rear exhaust section
   With all connections and hangers disconnected, carefully maneuver the rear exhaust section downward and out from under the vehicle. The section may require rotation or angling to clear the rear suspension components and subframe. Inspect the removed section for holes, cracks, or excessive corrosion.
7. 7

   Clean flange surfaces and inspect components
   Using a wire brush, thoroughly clean both exhaust flange mating surfaces on the remaining exhaust pipes. Remove all old gasket material, carbon buildup, and corrosion to ensure proper sealing. Inspect the flange surfaces for warping or damage. Check rubber hangers for cracking or deterioration and replace if necessary.
8. 8

   Install new rear exhaust section
   Position the new rear exhaust section into place, aligning it with the front flange connection first. Install a new exhaust flange gasket between the flanges. Loosely start the front flange bolts by hand to hold the section in position. Do not fully tighten yet.
9. 9

   Connect rear flange and align exhaust
   Install a new exhaust flange gasket at the rear connection. Align the rear exhaust section with the muffler or tailpipe flange and loosely install the rear flange bolts by hand. Verify that the exhaust pipe is properly aligned with adequate clearance from the rear suspension, fuel tank, and body panels (minimum 10-15mm clearance recommended).
10. 10

    Install exhaust hangers
    Attach the exhaust pipe loops to the rubber hangers. If removed, install the hanger bolts through the hangers and into the vehicle body mounting points. Hand-tighten the hanger bolts only at this stage to allow for final alignment adjustment.
11. 11

    Torque flange bolts
    Apply anti-seize compound to the threads of all exhaust flange bolts. Starting with the front flange connection, torque the flange bolts to specification using a crisscross pattern. Then torque the rear flange bolts to specification using the same pattern. Verify the exhaust alignment has not shifted during tightening.
    Torque spec

    Exhaust Flange Bolts45 Nm (33 lb-ft)
12. 12

    Torque hanger and heat shield bolts
    Torque all exhaust hanger bolts to specification. If equipped, reinstall the heat shield and torque the heat shield bolts to specification. Perform a final visual inspection to confirm all fasteners are installed and the exhaust has proper clearance throughout its length.
    Torque spec

    Hanger Bolts19 Nm (14 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)
13. 13

    Reconnect oxygen sensor (if applicable)
    Reconnect the rear oxygen sensor electrical connector, ensuring it clicks securely into place. Verify the wiring is routed away from hot exhaust components and moving suspension parts.

Reassembly

1. Double-check all flange bolts, hanger bolts, and heat shield bolts are torqued to specification
2. Verify minimum 10-15mm clearance exists between exhaust components and all surrounding parts including fuel lines, brake lines, suspension components, and body panels
3. Ensure all rubber hangers are properly seated and not twisted

Verification

• Carefully lower the vehicle from jack stands
• Start the engine and listen for exhaust leaks at both flange connections - a ticking or hissing sound indicates a leak
• With the engine running, have an assistant observe the exhaust system while you rev the engine to 2500-3000 RPM to check for excessive movement or contact with vehicle components
• Perform a test drive and listen for rattles, vibrations, or exhaust leaks under acceleration and deceleration
• After the test drive and cool-down period, re-inspect all flange connections for signs of leakage (soot marks) and verify all fasteners remain tight

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