This procedure covers the removal and replacement of the intermediate exhaust pipe on a 2015 Kia Forte with the 1.8L I4 engine, including exhaust flange disconnection and rubber hanger removal.

Warnings

Tools required

Parts

• Intermediate exhaust pipe × 1 — Use OEM specification
• Exhaust flange gasket (front) × 1 — Use OEM specification
• Exhaust flange gasket (rear) × 1 — Use OEM specification
• Exhaust flange bolts/nuts × 4 — Use OEM specification or high-temp stainless

Preparation

1. Ensure engine and exhaust system are completely cool to the touch
2. Park vehicle on level ground and engage parking brake
3. Place wheel chocks behind rear wheels
4. Apply penetrating oil to all exhaust flange bolts and allow to soak for 30 minutes
5. Raise front of vehicle using floor jack at designated lift points
6. Support vehicle securely on jack stands rated for vehicle weight
7. Lower jack slightly to ensure vehicle is stable on stands

Procedure

1. 1

   Remove heat shield (if equipped)
   Locate any heat shields covering the intermediate pipe. Using a 10mm socket, remove the heat shield mounting bolts. Carefully remove the heat shield and set aside for reinstallation.
   Torque spec

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

   Disconnect front exhaust flange
   Locate the front flange connection between the catalytic converter/downpipe and the intermediate pipe. Using a 14mm socket, remove the two flange bolts and nuts. Separate the flange connection and remove the old gasket. Inspect flange surfaces for damage or warping.
   ⚠Flange bolts may be severely corroded. If bolts break, use a bolt extractor set or drill out remaining stud material.
   Torque spec

   Exhaust Flange Bolts45 Nm (33 lb-ft)
3. 3

   Disconnect rear exhaust flange
   Locate the rear flange connection between the intermediate pipe and the rear muffler section. Using a 14mm socket, remove the two flange bolts and nuts. Separate the flange connection and remove the old gasket. Note the orientation of any alignment tabs.
   Torque spec

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

   Remove exhaust hanger support
   Locate the rubber exhaust hanger(s) supporting the intermediate pipe (typically 1-2 hangers mid-section). Using a pry bar or by hand, carefully work the metal hanger loops out of the rubber isolators. Spray with soapy water if needed to aid removal.
   ℹ️Avoid excessive force on rubber hangers as they can tear. Gentle twisting motion works better than pulling straight out.
5. 5

   Remove intermediate pipe
   With all connections and hangers disconnected, maneuver the intermediate pipe downward and rearward to remove from vehicle. Take care not to damage oxygen sensor wiring if routed near the pipe. Inspect removed pipe for damage, rust perforation, or internal blockage.
6. 6

   Clean flange surfaces and inspect hangers
   Using a wire brush and scraper, thoroughly clean both front and rear flange mating surfaces on the catalytic converter and rear muffler section. Remove all old gasket material, rust, and carbon buildup. Ensure surfaces are flat and smooth. Inspect rubber hangers for tears, cracks, or excessive softening and replace if worn.
7. 7

   Prepare new intermediate pipe
   Inspect new intermediate pipe for shipping damage and confirm correct fitment. Install new exhaust flange gaskets onto both front and rear flanges of the new pipe. Apply a thin coat of anti-seize compound to all exhaust flange bolt threads.
   ℹ️Do not apply anti-seize to flange mating surfaces or gaskets, only to bolt threads.
8. 8

   Install intermediate pipe
   Maneuver new intermediate pipe into position from underneath vehicle. Align rear flange first with muffler section, ensuring gasket is properly seated. Insert rear flange bolts finger-tight. Then align front flange with catalytic converter/downpipe and insert front flange bolts finger-tight. Do not fully tighten yet.
9. 9

   Install exhaust hangers
   Using a pry bar or by hand, install the intermediate pipe metal hanger loops into the rubber isolators. Ensure hangers are fully seated. The pipe should hang without binding or pulling when hangers are installed.
10. 10

    Align and torque exhaust flanges
    Check that both flanges are properly aligned with no gaps around gaskets. Starting with the rear flange, torque both flange bolts evenly in a cross-pattern to specification. Then torque the front flange bolts to specification in the same manner. Verify gaskets have not shifted during tightening.
    ℹ️Torque both flanges evenly to prevent gasket distortion and potential exhaust leaks.
    Torque spec

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

    Reinstall heat shield
    If heat shield was removed, position it back over the intermediate pipe ensuring proper clearance to all components. Install heat shield bolts and torque to specification.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Double-check all exhaust flange connections are torqued to specification
2. Verify all exhaust hangers are properly seated in rubber isolators
3. Ensure adequate clearance between intermediate pipe and underbody components, fuel lines, and brake lines
4. Remove jack stands and carefully lower vehicle to ground

Verification

• Start engine and allow to idle. Listen for exhaust leaks at both flange connections - a ticking or hissing sound indicates a leak
• Visually inspect both flanges while engine is running for signs of exhaust gas escaping
• Rev engine to 2500-3000 RPM and verify no abnormal exhaust sounds or rattles
• Check that intermediate pipe does not contact underbody or suspension components during idle or when revving
• After test drive, re-inspect flange connections and verify no exhaust staining or soot indicating leaks
• If any leaks are detected, allow system to cool and re-torque flange bolts to specification

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