Hyundai 28510-2BEF1 Exhaust Manifold Catalytic Assembly

Because of a Federally mandated extended warranty which covers emissions-related components such as the catalytic converter, check with a dealer service department before replacing the converter at your own expense. The catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust gas stream. Early models are equipped with two catalytic converters; one at the exhaust manifold and one under the vehicle. Later models have only one converter, either integral with the exhaust manifold or in the exhaust system under the vehicle. The test equipment for a catalytic converter is expensive and highly sophisticated. If you suspect that the converter on your vehicle is malfunctioning, take it to a dealer service department or an authorized emissions inspection facility for diagnosis and repair. Trouble code readout may indicate some converter problems. Whenever the vehicle is raised for servicing of underbody components, check the converter for leaks, corrosion, dents and other damage. Check the welds/flange bolts that attach the front and rear ends of the converter to the exhaust system. If damage is discovered, the converter should be replaced. Converter replacement requires removal of the exhaust manifold or a portion of the exhaust system.

The catalytic converter is an integral part of the exhaust manifold and cannot be removed from it. To begin removal, disconnect the negative cable from the battery, then remove the air filter housing. Next, disconnect the oxygen sensor electrical connectors, and if replacing the exhaust manifold, remove the sensors. In the engine compartment, remove the upper heat shield from the manifold. Raise the front of the vehicle and support it securely on jackstands. Remove the exhaust manifold support bracket bolts and the bracket if equipped. Apply penetrating oil to the nut bolts retaining the manifold, and after they have soaked, remove the nuts/bolts retaining the manifold to the cylinder head. Detach the manifold from the cylinder head, taking care not to damage the oxygen sensors, and discard the gasket. For installation, use a scraper to remove all traces of old gasket material and carbon deposits from the mating surfaces of the manifold and cylinder head. If the gasket shows signs of leaking, check the manifold for warpage with a straightedge and compare your readings. If warped, the manifold must be resurfaced or replaced. Position a new gasket over the cylinder head studs, noting any directional marks or arrows. Install the manifold and thread the mounting nuts/bolts into place. Working from the center out, tighten the nuts/bolts to the specified torque in three or four equal steps. Reinstall the remaining parts in the reverse order of removal, then run the engine and check for exhaust leaks.

Disconnect the oxygen sensor electrical connector, if equipped, and remove the oxygen sensor if necessary.