Hyundai Tucson: Intake And Exhaust System / Exhaust Manifold

- Components

1. Exhaust manifold
2. Exhaust manifold gasket
3. Exhaust manifold stay

• Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising the vehicle using the lift.(Refer to General Information - "Lift and Support Points")

• To prevent scalding by the hot exhaust parts, wait until the engine cools down to room temperature.

• Use fender covers to avoid damaging painted surfaces.

• When handling the metal gasket, be careful not to fold or damage the surface.

• To avoid damage, disconnect the wiring connectors carefully.

• Replace all gaskets with new ones. Do not reuse.

1.Disconnect the negative battery terminal.

2.Remove the engine cover.(Refer to the Engine And Transaxle Assembly - "Engine Cover")

3.Remove the engine room under cover.(Refer to the Engine And Transaxle Assembly - "Engine Room Under Cover")

4.Remove the front muffler.(Refer to the Intake And Exhaust System - "Muffler")

5.Disconnect the engine wiring connectors and harness clamps around the exhaust manifold.

6.Remove the oxygen sensor connector (A) from the wiring bracket.

7.Remove the EGR cooler pipe A (A).

Tightening torque: Bolt : 29.4 - 34.3 N.m (3.0 - 3.5 kgf.m, 21.7 - 25.3 lb-ft)Nut : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

8.Remove the exhaust manifold stay (A) after loosening the mounting bolts (B, C).

Tightening torqueBolt (B) : 18.6 - 27.5 N.m (1.9 - 2.8 kgf.m, 13.7 - 20.3 lb-ft)Bolt (C) : 52.0 - 57.9 N.m (5.3 - 5.9 kgf.m, 38.3 - 42.7 lb-ft)

9.Remove the exhaust manifold (A).

Tightening torque: 49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

• When installing the exhaust manifold, tighten the nuts with pre-torque first, and then tighten the nuts with the specified torque as the sequence shown.

10.Remove the exhaust manifold gasket (A).

• Do not reuse the exhaust manifold gasket.

11.Install in the reverse order of removal.