Sonata V6-3.0L (1991)
Exhaust Manifold: Service and Repair
Fig. 4 Exhaust Manifold Removal & Installation
1.
Disconnect battery ground cable.
2.
Tape and isolate battery ground cable terminal. Wait at least 30 seconds before proceeding.
3.
On all models, raise and support vehicle.
4.
Disconnect exhaust pipe from rear (left) exhaust manifold, Fig. 4.
5.
Remove EGR tube from rear (left) manifold, then disconnect oxygen sensor lead.
6.
Remove cross over pipe attaching bolts, then the cross over pipe.
7.
Remove rear (left) manifold attaching bolts, then the rear (left) manifold.
8.
Lower vehicle, then remove heat shield attaching bolts from front (right) exhaust manifold, then the heat shield.
9.
Remove cross over pipe to front (right) exhaust manifold attaching bolts.
10.
Remove front (right) exhaust manifold attaching bolts, then the front (right) exhaust manifold.
11.
Reverse procedure to install, noting the following:
a. Discard gaskets and clean gasket surfaces on both manifolds and cylinder head.
b. Use a straightedge to ensure gasket surfaces on manifolds are flat and within .004-.008 inch per foot of manifold length.
c. Tighten rear (left) exhaust manifold attaching bolts to specifications.
d. Tighten exhaust pipe to exhaust manifold attaching bolts to specifications.
e. Tighten crossover pipe to manifold attaching bolts to specifications.
f.
Tighten front (right) exhaust manifold attaching bolts to specifications, then install heat shield and tighten bolts to specifications.
