Hyundai Coupes/Sedans 1986-1993 Repair Guide

Exhaust Manifold

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Exhaust system fasteners are notorious for rusting which makes removing them without snapping or rounding an almost impossible task. Before working on any exhaust system component, identify which flanges, brackets, U-bolts, manifold, etc. have to be removed and inspect the material condition of the fasteners. If necessary, wire brush any rusted fastener to remove loose rust particles, then spray the area with penetrating oil and allow it to soak overnight.

REMOVAL & INSTALLATION



1468cc and 1495cc Engines

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable. Remove the air cleaner. Remove the heat stove and/or heat shield on the exhaust manifold, if equipped. With the manifold cool, soak all manifold nuts and studs with a liquid penetrant.
  2.  



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Fig. Fig. 1: Exhaust manifold bolt locations-1986-89 1468cc carbureted engine



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Fig. Fig. 2: Exhaust manifold mounting-1990-93 1468cc engine



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Fig. Fig. 3: Exhaust manifold mounting-1495cc engine

  1. Disconnect the exhaust pipe at the exhaust manifold. Disconnect and remove the oxygen sensor. If there is a secondary air line connected to the exhaust manifold, disconnect it. On turbocharged Scoupe models, disconnect the air intake hose from the turbocharger. First remove the exhaust pipe, then the secondary air supply pipe.
  2.  
  3. Support the manifold and remove all attaching nuts and washers. Slide the manifold from the cylinder head. Remove the converter mounting bolts. When the converter is disconnected, remove the exhaust manifold. If necessary, rock it to break it loose.
  4.  
  5. Thoroughly clean the sealing surfaces on the cylinder head and manifold. Replace any nuts, washers or studs that are excessively rusted or may have been damaged during removal. Use a straightedge to check the manifold and cylinder head sealing surfaces for flatness. Correct problems by replacing the manifold or machining the cylinder head surface.
  6.  

To install:
  1. Install new gaskets in such a way that all bolt holes and ports are aligned.
  2.  
  3. Make sure all the nuts turn freely, oiling them lightly, if necessary. Also, make sure all the studs are screwed all the way into the block.
  4.  
  5. Place the manifold in position and support it, install all washers and nuts hand tight.
  6.  
  7. Torque the exhaust manifold-to-cylinder head nuts to 14 ft. lbs. (20 Nm), alternately and in several stages on non-turbocharged engines. On turbocharged engines, torque the mounting nuts to 18-25 ft. lbs. (25-35 Nm).
  8.  
  9. Install piping, heat stoves and shields. Connect the exhaust pipe or primary catalytic converter. On turbocharged engines, connect the air intake line to the turbocharger.
  10.  
  11. Connect the negative battery cable. Operate the engine and check for leaks.
  12.  

2351cc Engine

See Figure 4



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Fig. Fig. 4: Exhaust manifold mounting-2351cc engine

  1. Disconnect the negative battery cable. Remove the air cleaner assembly.
  2.  
  3. Disconnect any EGR or heat lines. Disconnect the reed valve, if equipped.
  4.  
  5. Remove the exhaust pipe support bracket from the engine block, if equipped.
  6.  
  7. Remove the exhaust pipe from exhaust manifold by removing the exhaust pipe flange nuts. It may be necessary to remove 1 nut or bolt from underneath the vehicle.
  8.  
  9. If equipped with a catalytic converter mounted between the exhaust manifold and exhaust pipe, remove the exhaust pipe and the secondary air supply pipe.
  10.  
  11. Remove the nuts mounting the exhaust manifold to the cylinder head. Slide the manifold from the cylinder head, to provide enough room to remove the converter mounting bolts. When the converter is disconnected, remove the exhaust manifold.
  12.  

To install:
  1. Installation is the reverse order of the removal procedure. Install the exhaust manifold with new gaskets. New gaskets should be used and on some engines, port liner gaskets are used.
  2.  
  3. Torque the exhaust manifold-to-cylinder head bolts to 14 ft. lbs. (20 Nm).
  4.  

1596cc, 1796cc and 1997cc Engines

See Figure 5

  1. Disconnect the negative battery cable. Remove the air cleaner. Remove the heat shield on the exhaust manifold. With the manifold cool, soak all manifold nuts and studs with a liquid penetrant.
  2.  



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Fig. Fig. 5: Exhaust manifold mounting-1596cc, 1796cc and 1997cc engines

  1. Disconnect the exhaust pipe at the exhaust manifold. Disconnect and remove the oxygen sensor.
  2.  
  3. Support the manifold and remove all attaching nuts and washers. Slide the manifold from the cylinder head.
  4.  
  5. Thoroughly clean the sealing surfaces on the cylinder head and manifold. Replace any nuts, washers or studs that are excessively rusted or may have been damaged during removal. Use a straightedge to check the manifold and cylinder head sealing surfaces for flatness. Correct problems by replacing the manifold or machining the cylinder head surface.
  6.  

To install:
  1. Install new gaskets in such a way that all bolt holes and ports are aligned.
  2.  
  3. Make sure all the nuts turn freely, oiling them lightly, if necessary. Also, make sure all the studs are screwed all the way into the block.
  4.  
  5. Place the manifold in position and support it, install all washers and nuts hand tight.
  6.  
  7. Torque the exhaust manifold-to-cylinder head nuts to 22 ft. lbs. (30 Nm), alternately and in several stages.
  8.  
  9. Connect the exhaust pipe.
  10.  
  11. Connect the negative battery cable. Operate the engine and check for leaks.
  12.  

2972cc Engine

See Figure 6

  1. Disconnect the negative battery cable. Raise the vehicle and support safely.
  2.  



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Fig. Fig. 6: Exhaust manifold mounting-2972cc engine

  1. Disconnect the exhaust pipe from the rear exhaust manifold at the articulated joint.
  2.  
  3. Disconnect the EGR tube from the rear manifold and unplug the oxygen sensor wire.
  4.  
  5. Remove the crossover pipe to manifold bolts.
  6.  
  7. Remove the rear manifold to cylinder head nuts and the manifold.
  8.  
  9. Lower the vehicle and remove the heat shield from the manifold.
  10.  
  11. Remove the front manifold-to-cylinder head nuts and the manifold.
  12.  
  13. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
  14.  

To install:
  1. When installing, the numbers 1-3-5 on the gaskets are used with the rear cylinders and 2-4-6 are on the gasket for the front cylinders. Torque the manifold-to-cylinder head nuts to 14 ft. lbs. (20 Nm).
  2.  
  3. Install the crossover pipe to the manifold.
  4.  
  5. Connect the EGR tube and oxygen sensor wire.
  6.  
  7. Connect the exhaust pipe to the rear exhaust manifold, at the articulated joint.
  8.  
  9. Connect the negative battery cable and check the manifolds for leaks.
  10.  

 
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