Hyundai 28510-38250 Exhaust Manifold Assembly

Disconnect the cable from the negative terminal of the battery. Spray penetrating oil on the exhaust manifold fasteners and allow it to soak in. If removing the rear exhaust manifold, raise the front of the vehicle and support it securely on jackstands, then remove the engine splash shield. Disconnect or remove the heated oxygen sensors from the manifold(s). Remove the bolts and the heat shield over the exhaust manifold. Remove the exhaust manifold brace, if equipped. Remove the nuts retaining the exhaust pipe(s) to the exhaust manifold(s) or catalytic converter(s). Unbolt the exhaust manifold(s) from the cylinder head(s), working from the ends toward the middle, and slip the manifold(s) off the mounting studs. Carefully inspect the manifold(s) and fasteners for cracks and damage. Use a scraper to remove all traces of old gasket material and carbon deposits from the manifold and cylinder head mating surfaces. If the gasket was leaking, check the manifold for warpage on the cylinder head mounting surface by placing a straightedge over the surface and trying to insert a feeler gauge; if the clearance exceeds the limit, have the manifold resurfaced at an automotive machine shop. Position a new gasket over the cylinder head studs, install the manifold(s), and thread the mounting nuts into place. Working from the center out, tighten the nuts to the specified torque. Reinstall the remaining parts in the reverse order of removal, using new gaskets when connecting the exhaust pipes. Run the engine and check for exhaust leaks.

Note that 2.5L and 2.7L engines come with exhaust manifold/catalytic converter assemblies, while 3.3L engines have conventional catalytic converters. Begin by disconnecting the cable from the negative terminal of the battery. Apply penetrating oil to the exhaust manifold fasteners and let it soak. Raise the front of the vehicle and securely support it on jackstands, then remove the engine lower splash shield. Disconnect or remove the heated oxygen sensors from the manifold(s), noting that there is an oxygen sensor immediately before and after each catalytic converter. Remove the bolts and the heat shield over the exhaust manifold, and take off the exhaust manifold brace if equipped. If it interferes, remove the dipstick and its tube on 3.3L engines. Detach the fasteners holding the exhaust pipe(s) to the exhaust manifold(s) or catalytic converter(s). Unbolt the exhaust manifold(s) from the cylinder head(s), starting from the ends and moving toward the middle, then slip the manifold(s) off the mounting studs. Carefully inspect the manifold(s) and fasteners for any cracks or damage. Use a scraper to eliminate all old gasket material and carbon deposits from the mating surfaces of the manifold and cylinder head. If the gasket was leaking, check for warpage on the cylinder head mounting surface by placing a straightedge over it and attempting to insert a feeler gauge; if the clearance exceeds the limit, have the manifold resurfaced at an automotive machine shop. Position a new gasket over the cylinder head studs, install the manifold(s), and thread the mounting nuts into place. Tighten the nuts to the specified torque, working from the center out. Reinstall the remaining parts in the reverse order of removal, using new gaskets when connecting the exhaust pipes. Finally, run the engine and check for any exhaust leaks.

Working in the engine compartment, remove the upper heat shield from the manifold.

Working in the engine compartment, remove the upper heat shield from the manifold. The upper oxygen sensor must be removed from 2006 and later engines in order to remove the exhaust manifold heat shield. On 2006 and later models, there is an exhaust manifold brace that must be unbolted from the manifold. Disconnect any other interfering brackets; these vary from vehicle to vehicle.