Hyundai Car 1999-05

Exhaust Manifold

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Removal & Installation





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Fig. Exploded view of the exhaust manifold and related components-1.5L engines



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Fig. Exploded view of the exhaust manifold components-Sonata 2.0L engines



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Fig. Exploded view of the exhaust manifold components-Elantra and Tiburon with 2.0L engine



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and related components-1.5L engines



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold components-1.8L and Sonata 2.0L engines



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold components-Elantra and Tiburon with 2.0L engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heat protector
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold and discard the gaskets
     

  4.  
  5. Clean and residual gasket material from all mating surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold-XG 300

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Heat protector and torque the bolts to 11 ft. lbs. (15 Nm)
     
    HO 2 S sensor
     
    Negative battery cable.
     

  2.  



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold and related components-1.5L engines



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold components-1.8L and Sonata 2.0L engines



Click image to see an enlarged view

Fig. Exploded view of the exhaust manifold components-Elantra and Tiburon with 2.0L engine

1.6L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold heat protector
     
    Exhaust manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the 1.6L exhaust manifold assembly

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 41 ft. lbs. (55 Nm)
     
    Exhaust manifold heat protector and torque the bolts to 15 ft. lbs. (20 Nm)
     
    HO 2 S sensor
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold heat protector
     
    Exhaust manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the 1.6L exhaust manifold assembly

     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 41 ft. lbs. (55 Nm)
     
    Exhaust manifold heat protector and torque the bolts to 15 ft. lbs. (20 Nm)
     
    HO 2 S sensor
     
    Negative battery cable
     

  2.  

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO2S) sensor
     
    Exhaust manifold heat shield
     
    Exhaust front pipe
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Install the exhaust manifold with a new gasket and torque the nuts to the following specifications:
    1. 1.5L engine: 11-15 ft. lbs. (15-20 Nm).
    2.  
    3. Sonata 2.0L engines: 18-22 ft. lbs. (25-30 Nm).
    4.  
    5. Elantra and Tiburon 2.0L engine: 32-41 ft. lbs. (43-50 Nm).
    6.  
    7. 2.4L engine: M8 fasteners to 18-22 ft. lbs. (25-30 Nm) and M10 fasteners to 25-40 ft. lbs. (34-55 Nm).
    8.  

  2.  
  3. Install or connect the following:

    Exhaust front pipe
     
    Exhaust manifold heat shield
     
    HO2S sensor
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold heat shield
     
    Exhaust front pipe
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Install the exhaust manifold with a new gasket and torque the nuts to the following specifications:
    1. 1.5L engine: 11-15 ft. lbs. (15-20 Nm).
    2.  
    3. 1.8L and Sonata 2.0L engines: 18-22 ft. lbs. (25-30 Nm).
    4.  
    5. Elantra and Tiburon 2.0L engine: 32-41 ft. lbs. (43-50 Nm).
    6.  
    7. 2.4L engine: M8 fasteners to 18-22 ft. lbs. (25-30 Nm) and M10 fasteners to 25-40 ft. lbs. (34-55 Nm).
    8.  

  2.  
  3. Install or connect the following:

    Exhaust front pipe
     
    Exhaust manifold heat shield
     
    HO 2 S sensor
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor
     
    Exhaust manifold heat shield
     
    Exhaust front pipe
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Install the exhaust manifold with a new gasket and torque the nuts to the following specifications:
    1. 1.5L engine: 11-15 ft. lbs. (15-20 Nm).
    2.  
    3. 1.8L and Sonata 2.0L engines: 18-22 ft. lbs. (25-30 Nm).
    4.  
    5. Elantra and Tiburon 2.0L engine: 32-41 ft. lbs. (43-50 Nm).
    6.  
    7. 2.4L engine: M8 fasteners to 18-22 ft. lbs. (25-30 Nm) and M10 fasteners to 25-40 ft. lbs. (34-55 Nm).
    8.  

  2.  
  3. Install or connect the following:

    Exhaust front pipe
     
    Exhaust manifold heat shield
     
    HO 2 S sensor
     
    Negative battery cable
     

  4.  
  5. Start the engine and check for leaks.
  6.  

6-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Exhaust Gas Recirculation (EGR) tube
     
    Oil dipstick tube
     
    Exhaust manifold heat shields
     
    Exhaust manifolds and discard the gasket
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds and torque the nuts to 11-16 ft. lbs. (15-22 Nm) for 3.0L and 3.5L engines or to 18-22 ft. lbs. (25-30 Nm) for 2.5L and 2.7L engines
     
    Exhaust manifold heat shields
     
    Oil dipstick tube
     
    EGR tube
     
    Exhaust front pipe and torque the nuts to 22-29 ft. lbs. (30-40 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heat protector
     
    Heated Oxygen (HO2S) sensor
     
    Exhaust manifold and discard the gaskets
     

  4.  
  5. Clean and residual gasket material from all mating surfaces.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold-XG 300 and XG 350


To install:

  1. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 22 ft. lbs. (30 Nm)
     
    Heat protector and torque the bolts to 11 ft. lbs. (15 Nm)
     
    HO2S sensor
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust front pipe
     
    Exhaust Gas Recirculation (EGR) tube
     
    Oil dipstick tube
     
    Exhaust manifold heat shields
     
    Exhaust manifolds and discard the gasket
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds and torque the nuts to 11-16 ft. lbs. (15-22 Nm) for 3.0L engines or to 18-22 ft. lbs. (25-30 Nm) for 2.5L engines
     
    Exhaust manifold heat shields
     
    Oil dipstick tube
     
    EGR tube
     
    Exhaust front pipe and torque the nuts to 22-29 ft. lbs. (30-40 Nm)
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

 
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