Hyundai Cars 2006-2008

Exhaust Manifold

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Removal & Installation



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

    The negative battery cable
     
    The under cover
     
    The LH, RH rear oxygen sensor connector from bracket
     
    The front muffler
     
    The oil level gauge
     
    The LH front oxygen sensor connector from bracket
     
    The LH heat protector
     
    The LH exhaust manifold
     
    The RH front oxygen sensor connector from bracket
     
    The RH heat protector
     
    The RH exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components

     

  4.  

To install:

  1. Install a new gasket and exhaust manifold. Tighten to 29-33 ft. lbs. (39-44 Nm).
  2.  
  3. Install heat protector. Tighten to 12-16 ft. lbs. (17-22 Nm).
  4.  
  5. Install front muffler. Tightening torque: 29-43 ft. lbs. (39-59 Nm).
  6.  
  7. Connect oxygen sensor connector.
  8.  
  9. Install under cover.
  10.  
  11. Connect the negative battery cable.
  12.  

1.6L, 2.0L & 2.4L Engines

Specific to:

Hyundai Accent 2006-2008

Hyundai Elantra 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008

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

    The negative battery cable
     
    The engine cover
     
    The front oxygen sensor connector
     
    The front muffler heat protector
     
    The front muffler
     
    The stay of the exhaust manifold and catalytic converter assembly
     
    The heat protector
     
    The exhaust manifold and catalytic converter assembly

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-1.6L engine



    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-2.0L engine



    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-2.4L engine

     

  4.  

To install:

  1. Install the exhaust manifold and catalytic converter assembly:
    1. 1.6L engine: Tighten to 22-25 ft. lbs. (29-34 Nm).
    2.  
    3. 2.0L engine: Tighten to 31-40 ft lbs. (42-54 Nm).
    4.  
    5. 2.4L engine: Tighten to 29-33 ft. lbs. (39-44 Nm).
    6.  

  2.  
  3. Install the heat protector:
    1. 1.6L engine: Tighten to 12-16 ft. lbs. (17-22 Nm).
    2.  
    3. 2.0L engine: Tighten to 12-16 ft. lbs. (17-22 Nm).
    4.  
    5. 2.4L engine: Tighten to 14-20 ft. lbs. (19-27 Nm).
    6.  

  4.  
  5. Install the stay of the exhaust manifold and catalytic converter assembly. Tighten large bolts to 25-29 ft. lbs. (34-39 Nm); smaller bolts to 22-29 ft. lbs. (29-39 Nm).
  6.  
  7. Install the front muffler. Tighten to 22-29 ft. lbs. (29-39 Nm).
  8.  
  9. Install the front muffler heat protector. Tighten to 72-108 inch lbs. (8-12 Nm).
  10.  
  11. Install or connect the following:

    The front oxygen sensor connector
     
    The engine cover
     
    The negative battery cable
     

  12.  

2.7L Engine

Specific to:

Hyundai Tiburon 2006-2008

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

    The negative battery cable
     
    The undercover
     
    The front muffler
     
    The oxygen sensor connector
     
    The heat protector
     
    The exhaust manifold and gasket

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-2.7L engine

     

  4.  

To install:

  1. Install the exhaust manifold and gasket. Tighten bolts to 18-22 ft. lbs. (25-29 Nm).
  2.  
  3. Install the heat protector. Tighten bolts to 12-16 ft. lbs. (17-22 Nm).
  4.  
  5. Connect the oxygen sensor connector.
  6.  
  7. Install the front muffler. Tighten to 22-29 ft. lbs. (29-39 Nm).
  8.  
  9. Install the undercover.
  10.  
  11. Connect the negative battery cable.
  12.  

3.3L & 3.8L Engines

Specific to:

Hyundai Azera 2006-2008

Hyundai Sonata 2006-2008

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

    The negative battery cable
     
    The undercover
     
    The LH, RH rear oxygen sensor connector from bracket
     
    The front muffler
     
    The oil level gauge
     
    The LH front oxygen sensor connector from bracket
     
    The LH heat protector
     
    The LH exhaust manifold
     
    The RH front oxygen sensor connector from bracket
     
    The RH heat protector
     
    The RH exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-3.3L and 3.8L engines

     

  4.  

To install:

  1. Install a new gasket and exhaust manifold. Tighten to 29-33 ft. lbs. (39-44 Nm).
  2.  
  3. Install heat protector. Tighten to 12-16 ft. lbs. (17-22 Nm).
  4.  
  5. Install front muffler. Tightening torque: 29-43 ft. lbs. (39-59 Nm).
  6.  
  7. Connect oxygen sensor connector.
  8.  
  9. Install undercover.
  10.  
  11. Connect the negative battery cable.
  12.  

 
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