Hyundai Sonata: Exhaust Manifold. Repair procedures - Intake And Exhaust System - Engine Mechanical SystemHyundai Sonata: Exhaust Manifold. Repair procedures

Removal and Installation

1.
Remove the engine cover.
2.
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).
4.
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)

5.
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).
7.
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]
8.
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.

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

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

    See also:

    Impact sensing door unlock system (if equipped)
    All doors will be automatically unlocked when the impact is delivered to impact sensors while the ignition switch is ON. However, the doors may not be unlocked if mechanical problems occur with th ...

    Battery. Description and Operation
    Description 1. The maintenance-free battery is, as the name implies, totally maintenance free and has no removable battery cell caps. 2. W ...

    Ventilation
    1. Set the mode to the position. 2. Set the air intake control to the outside (fresh) air position. 3. Set the temperature control to the desired position. 4. Set the fan speed control to the desi ...