This procedure covers the removal and replacement of the exhaust resonator on a 2015 Kia Forte with 1.8L I4 engine, including disconnection from the catalytic converter and muffler sections.

Warnings

Tools required

Parts

• Exhaust resonator assembly × 1 — Use OEM specification
• Exhaust flange gasket × 2 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Allow exhaust system to cool completely if vehicle was recently driven
4. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer's lift points
5. Apply penetrating oil to all exhaust flange bolts and clamp fasteners, allow to soak for at least 15 minutes

Procedure

1. 1

   Inspect exhaust system layout
   From underneath the vehicle, locate the resonator assembly positioned between the catalytic converter and rear muffler. Identify the front flange connection to the catalytic converter, the rear connection point (clamp or flange), and the rubber exhaust hangers supporting the resonator. Note the routing and clearance to the fuel tank and rear suspension components.
2. 2

   Disconnect rear exhaust connection
   At the rear of the resonator, loosen and remove the exhaust clamp or flange bolts connecting to the rear muffler section. If equipped with a clamp, remove the two fasteners completely. If equipped with a flange, remove both flange bolts. Support the rear exhaust section to prevent it from dropping.
   Torque spec

   Exhaust Clamps55 Nm (41 lb-ft)

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

   Disconnect front flange connection
   At the front of the resonator where it connects to the catalytic converter, remove the two flange bolts using a 14mm socket. Keep track of any springs or washers on these bolts. Support the resonator to prevent it from falling once disconnected.
   ⚠If bolts are severely corroded and break, you may need to drill out studs or replace the catalytic converter flange. Work carefully to avoid damaging the catalytic converter.
   Torque spec

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

   Remove exhaust hanger supports
   Locate the rubber exhaust hangers supporting the resonator (typically one or two hangers). Using a pry bar or exhaust hanger removal tool, carefully unhook the metal loops from the rubber grommets. Work the resonator side-to-side to assist in releasing the hangers. Inspect rubber grommets for cracking or deterioration and replace if necessary.
5. 5

   Remove resonator assembly
   With all connections and hangers released, carefully lower and remove the resonator assembly from the vehicle. Maneuver it past the fuel tank, suspension components, and driveline. Note the orientation and routing for installation of the new resonator.
6. 6

   Clean flange surfaces
   Using a wire brush, thoroughly clean the mating flange surfaces on both the catalytic converter and the rear exhaust pipe. Remove all traces of old gasket material, carbon buildup, and corrosion. Ensure surfaces are flat and smooth for proper sealing with new gaskets.
7. 7

   Install new exhaust gaskets
   Place new exhaust flange gaskets onto the catalytic converter outlet flange and the rear pipe connection point. Ensure gaskets are properly centered over the bolt holes and pipe openings.
8. 8

   Position new resonator
   Maneuver the new resonator into position under the vehicle, routing it in the same path as the original component. Align the front flange with the catalytic converter outlet and the rear connection with the muffler inlet pipe. Ensure proper clearance from fuel tank, heat shields, and suspension components.
9. 9

   Install exhaust hangers
   Hook the resonator's metal hanger loops into the rubber grommets on the vehicle body. Use a lubricant like soapy water on the rubber grommets if needed to ease installation. Ensure the resonator is properly supported before proceeding with fasteners.
10. 10

    Install and tighten front flange connection
    Install the two front flange bolts connecting the resonator to the catalytic converter outlet. Start both bolts by hand, then tighten evenly in a cross pattern using a torque wrench to the specified torque. Ensure the gasket remains properly seated during tightening.
    Torque spec

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

    Install and tighten rear connection
    At the rear connection to the muffler, install the exhaust clamp or flange bolts. If using a clamp, position it evenly over the joint before tightening. Tighten clamp fasteners or flange bolts to the specified torque using a torque wrench. Ensure proper alignment of all exhaust sections.
    Torque spec

    Exhaust Clamps55 Nm (41 lb-ft)

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

    Verify exhaust alignment and clearance
    Visually inspect the entire exhaust system to ensure proper alignment. Verify adequate clearance between the resonator and all surrounding components including fuel tank, heat shields, suspension arms, and driveline. Adjust hanger positions if necessary to achieve proper positioning. The exhaust should hang straight with no contact points or binding.

Reassembly

1. Double-check all fastener torque values before lowering vehicle
2. Ensure all rubber exhaust hangers are properly seated
3. Verify no tools or parts were left under the vehicle

Verification

• Lower vehicle from jack stands and remove wheel chocks
• Start engine and listen for exhaust leaks at both resonator connections - there should be no hissing or ticking sounds
• Rev engine to 2500-3000 RPM and verify no abnormal exhaust noise
• Allow engine to reach operating temperature and recheck for leaks
• Visually inspect underneath vehicle while engine is running to confirm no exhaust gases escaping from joints
• Take a short test drive and verify proper exhaust tone and no rattles or contact with undercarriage
• After test drive, perform final inspection of all connections and verify resonator has not shifted position

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