Removal and replacement of the tail pipe section on a 2015 Kia Forte 1.8L I4, including disconnecting from the muffler or resonator and releasing rubber hangers.

Warnings

Tools required

Parts

• Tail pipe assembly × 1 — Use OEM specification or compatible aftermarket
• Exhaust flange gasket × 1 — Use OEM specification
• Rubber exhaust hangers (if damaged) × 1 — Inspect and replace as needed

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind front wheels
3. Ensure exhaust system is completely cool to the touch
4. Raise rear of vehicle using floor jack and secure with jack stands at manufacturer-recommended lift points
5. Inspect tail pipe routing and identify connection point to muffler or resonator
6. Spray penetrating oil on flange bolts and rubber hanger connection points, allow to soak for 10-15 minutes

Procedure

1. 1

   Locate and support tail pipe
   Position yourself under the rear of the vehicle and locate the tail pipe assembly. Identify the flange connection (typically between muffler and tail pipe) and rubber hanger locations. The 2015 Forte 1.8L typically has 1-2 rubber hangers supporting the tail pipe section. Visually inspect for any heat shields that may need removal.
2. 2

   Remove heat shield if present
   If a heat shield is present over the tail pipe flange connection, remove the retaining bolts using a 10mm socket. Set heat shield and bolts aside for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Remove flange bolts
   Locate the two-bolt flange connection between the muffler and tail pipe. Using a 14mm wrench or socket on the nut side and a 14mm wrench on the bolt side, loosen and remove both flange bolts and nuts. If bolts are seized, apply additional penetrating oil and use penetrating tapping motions to break corrosion. Keep the old gasket if it comes out intact for comparison with replacement.
   ⚠Support tail pipe with one hand while removing final bolt to prevent it from dropping suddenly.
   Torque spec

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

   Separate flange connection
   Once bolts are removed, carefully pull the tail pipe rearward to separate the flange connection. There may be some resistance due to corrosion or gasket adhesion. Gently twist and pull to separate. Remove and discard the old flange gasket.
5. 5

   Release rubber hangers
   Support the tail pipe weight with one hand. Using a pry bar or by hand with gloves, push or pull the rubber hanger isolators off their mounting studs. The 2015 Forte tail pipe typically has rubber hangers near the rear axle area. Work the rubber grommets off the metal hangers by pushing the pipe to create slack, then pulling the rubber free from the hanger hook. Lower the tail pipe and remove from vehicle.
6. 6

   Clean flange mating surface
   Using a wire brush, thoroughly clean the flange surface on the muffler or resonator where the tail pipe connects. Remove all old gasket material, rust, and carbon deposits to ensure a proper seal with the new gasket. Inspect flange for cracks or damage.
7. 7

   Inspect and prepare rubber hangers
   Inspect the rubber exhaust hangers on the vehicle chassis for cracks, tears, or deterioration. Replace any damaged hangers. If hangers are in good condition, apply a small amount of penetrating oil or dish soap to the hanger studs to ease installation of the new tail pipe.
8. 8

   Install new tail pipe onto hangers
   Position the new tail pipe under the vehicle and align with the rubber hanger locations. Work the rubber grommets on the tail pipe over the chassis hanger studs, starting with the rearmost hanger. Use a pry bar or pull the pipe to create enough slack to hook each rubber isolator onto its mounting point. Ensure all hangers are fully seated.
   ℹ️Do not fully tighten flange bolts until all hangers are installed to allow for alignment adjustment.
9. 9

   Install new flange gasket
   Position the new exhaust flange gasket over the studs or bolt holes at the muffler connection point. Ensure the gasket is properly aligned and seated flush against the flange surface.
10. 10

    Connect and align tail pipe flange
    Slide the tail pipe forward to engage the flange connection with the muffler or resonator. Align the bolt holes in both flanges. Insert both flange bolts through the flanges from the appropriate side. Hand-thread the nuts onto the bolts. Do not tighten yet.
11. 11

    Apply anti-seize and torque flange bolts
    Apply a thin coat of anti-seize compound to the exposed threads of the flange bolts. Using a torque wrench, tighten the flange bolts in a cross-pattern to the specified torque of 45 Nm (33 lb-ft). Verify the tail pipe hangs evenly and the outlet is positioned properly with adequate clearance from the bumper and body panels. Adjust hanger positions if necessary before final torque.
    Torque spec

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

    Reinstall heat shield
    If a heat shield was removed, position it back over the flange connection and install the retaining bolts. Torque heat shield bolts to 10 Nm (7 lb-ft).
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Verify all flange bolts are torqued to specification and anti-seize was applied
2. Ensure tail pipe outlet has adequate clearance from bumper and body (minimum 1 inch recommended)
3. Check that all rubber hangers are fully seated and supporting the tail pipe evenly
4. Lower vehicle from jack stands

Verification

• Start engine and listen for exhaust leaks at the flange connection while engine is at idle
• Have an assistant rev engine to 2000-2500 RPM while you inspect flange area for any visible exhaust gas escaping
• Visually confirm tail pipe position remains stable and does not contact body panels or suspension components
• Check for excessive movement in rubber hangers during engine rev
• Take a short test drive and re-inspect flange connection for any signs of leaks or loosening

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