Hyundai Sonata: Exhaust Manifold. Repair procedures

Removal and Installation

1.	Remove the engine cover.

Disconnect the battery negative terminal.

Tightening torque

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

3.	ULEV : Disconnect the front oxygen sensor connector (A). SULEV : Disconnect the front oxygen sensor connector (A) and the rear oxygen sensor connector (B).

Remove the front muffler (A).

Tightening torque:

39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

ULEV : Remove the exhaust manifold heat protector (A).

Tightening torque :

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

SULEV : Using the SST (09392-2H100) (A), remove the front oxygen sensor (B) and the remove the exhaust manifold heat protector (C).

Tightening torque

Oxygen sensor:

39.2~ 49.0N.m (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)

Heat protector bolts:

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

6.	Remove the driveshaft heat protector (A).

Remove the exhaust manifold stay (A).

Tightening torque :

M8 :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)

M10 : 51.9 ~ 57.8.m (5.3 ~ 5.9kgf.m, 38.3 ~ 42.6lb-ft)

[ULEV]

[SULEV]

Remove the exhaust manifold (A) with the gasket (B).

Tightening torque

49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.7lb-ft)

[ULEV]

[SULEV]

When installing, replace with a new gasket.

When installing the intake manifold, tighten the nuts with pre-torque first, and then tighten the nuts with specified torque in the sequence shown.

[ULEV]

[SULEV]

9.	Installation is reverse order of removal.

Components [ULEV] 1. Heat protector 2. Exhaust manifold 3. Exhaust manifold gasket 4. Exhaust manifold stay [SULEV] 1. Heat protec ...

Components 1. Front muffler 2. Catalytic converter & center muffler assembly 3. Main muffler 4. Gasket 5. Hanger ...