Hyundai Sonata: Intake And Exhaust System / Exhaust Manifold Repair procedures

Removal and Installation
1.
Remove the engine cover.
2.
Disconnect the battery negative terminal.
3.
Remove the air cleaner assembly. (Intake And Exhaust System - "Air Cleaner")
4.
Remove the front muffler. (Intake And Exhaust System - "Muffler")
5.
Remove the intercooler inlet hoses & pipe (A).

Tightening torque
Bolt :
19.6 ~ 26.4 N.m (2.0 ~ 2.7 kgf.m, 14.4 ~ 19.5 lb-ft)
Clamp :
4.9 ~ 6.8 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.0 lb-ft)

6.
Remove the turbo charger actuator solenoid valve(A).

7.
Remove the intake pipe stay(A).

Tightening torque
M8 Bolt :
18.6 ~ 23.5 N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4 lb-ft)
M10 Bolt :
29.4 ~ 34.3 N.m (3.0 ~ 3.5kgf.m, 21.6 ~ 25.3 lb-ft)

8.
Remove the intake pipe(B) and gasket.

Tightening torque
Bolt :
29.4 ~ 39.2N.m (3.0 ~ 4.0 kgf.m, 21.6 ~ 28.9 lb-ft)
Nut :
35.3 ~ 41.1 N.m (3.6 ~ 4.2 kgf.m, 26.0 ~ 30.3 lb-ft)

9.
Remove the turbo charger water pipe & hose(A).

Tightening torque
Flange Bolt :
9.8 ~ 11.8N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Eye Nut :
26.4 ~ 32.3 N.m (2.7~ 3.3 kgf.m, 19.5 ~ 32.3 lb-ft)

10.
Remove the turbo manifold module heat protect(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

   
When installing, temporarily tighten the bolt and then completely tighten to specified torque.
11.
Remove the turbo DPF(A).

Tightening torque :

12.
Remove the turbo charger oil feed pipe(A).

Tightening torque
M6 Bolt :
9.8 ~ 11.8N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Eye Nut :
11.8 ~ 17.6 N.m (1.2 ~ 1.8 kgf.m, 8.7 ~ 41.1 lb-ft)

   
When installing, completely remove the oil from assembly part and be careful not to enter any dust.
When installing the eye bolt, be careful to not contact with the stopper to the compressor housing.
13.
Remove the turbo charger oil drain pipe(A).

Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft

   
When installing, completely remove the oil from assembly part.
14.
Remove the turbo charger stay(A).

Tightening torque :
49.0 ~ 53.9N.m (5.0 ~ 5.5 kgf.m, 36.1 ~ 39.7 lb-ft)

   
When installing, temporarily tighten the bolt in picture order and completely tighten the bolt as specified torque in order.
15.
Remove the turbo manifold module(A) and gasket.

Tightening torque :
35.3 ~ 41.1N.m (3.6 ~ 4.2 kgf.m, 26.0 ~ 30.3 lb-ft)

   
When installing, you should assemble it toward the coating side(black).
When installing, temporarily tighten the nut in picture order and completely tighten the bolt as specified torque in order.

16.
Install in the reverse order of removal.
   
When installing, replace with a new gasket.
If the oil feed pipe and hose is damaged, the turbocharger could be damaged because turbocharger oil supply is not good. Be careful to not crush.
Exhaust Manifold Components and Components Location
Components 1. Turbo manifold gasket2. Turbo manifold module3. Turbo charger coupler4. Turbo charger coupler & gasket5. Oil feed pipe & hose assembly6. Oil drain pipe assembly7. Turbo mani ...

Intercooler Components and Components Location
Components 1. Intercooler air guard2. Intercooler3. Intercooler outlet hose4. Intercooler inlet hose & pipe5. Intercooler upper mounting bracket6. Intercooler lower mounting insulator7. Inter ...

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