Hyundai Santa Fe (TM): Intake And Exhaust System - Engine Mechanical SystemHyundai Santa Fe (TM): Intake And Exhaust System

Air Cleaner. Repair procedures

Removal and Installation
Air Cleaner Assembly
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine And Transaxle Assembly - “Engine Cover”)
3.
Remove the air duct (A).

4.
Remove the air cleaner assembly.
(1)
Disconnect the breather hose A (A).
(2)
Disconnect the breather hose B (B).
(3)
Disconnect the air intake hose (C) and then remove the air cleaner assembly (D).
Tightening torque
Hose clamp :
2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
Air cleaner bolts :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)

5.
Install in the reverse order of removal.
Air Cleaner Element Replacement
1.
Open the air cleaner element cover (A) by lifting up the air cleaner element cover handle.

2.
Unlock the air cleaner element camshaft (A) by turning in the direction of arrow.

3.
Replace the air cleaner element (A) with a new one.

  
Grab the handle then pull out the air cleaner element.
4.
Lock the air cleaner element camshaft and then close the air cleaner element cover.

Intake Manifold. Repair procedures

Removal and Installation
1.
Disconnect the battery negative teminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
3.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
4.
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.

5.
Disconnect the purge control solenoid valve (PCSV) hose (A) and vacuum hose (B).

6.
Remove the purge control solenoid valve (PCSV) bracket (A) from intake manifold.
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

7.
Remove the wiring bracket (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

8.
Remove the breather hose mounting bolt (A)
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

9.
Remove the intake manifold stay.
(1)
Disconnect the fastener (A) from intake manifold stay
(2)
Remove the intake manifold stay (B).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

10.
Remove the Intake Manifold (A).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

11.
Remove the electronic throttle control (ETC) module.
(Refer to Engine Control/ Fuel System - "ETC (Electronic Throttle Control")
12.
Install in the reverse order of removal.
  
When installing, replace with new gaskets.
When installing the intake manifold, tighten sequence shown.

Exhaust Manifold. Repair procedures

Removal and Installation
  
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")
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly System - "Engine cover")
3.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly System - "Engine Room Under Cover")
4.
Disconnect the front oxygen sensor connectors (A).

5.
Remove the front muffler.
(Refer to Intake and Exhaust Manifold - "Front Muffler")
6.
Remove the exhaust manifold stay (A).
Tightening torque :
Bolts (B) : 18.6 - 27.5 N.m (1.9 - 2.8 kgf.m, 13.7 - 20.3 lb-ft)
Bolts (C) : 52.0 - 57.9 N.m (5.3 - 5.9 kgf.m, 38.3 - 42.7 lb-ft)

7.
Remove the drive shaft heat protector (A).
Tightening torque
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

8.
Remove the engine mounting support bracket.
(Refer to Engine and Transaxle Assembly - "Engine Mounting")
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)

10.
Remove the exhaust manifold gasket (A).

11.
Install in the reverse order of removal.
  
When installing the exhaust manifold, with a new gasket.
When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with specified torque in the sequence shown.

Muffler. Repair procedures

Removal and Installation
  
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")
[Front Muffler]
1.
Disconnect the battery negative terminal.
2.
Disconnect the oxygen sensor connector (A) and then disconnect from bracket.

3.
Remove the engine room rear under cover (A).
Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)

4.
Remove the front muffler (A).
Tightening torque :
Muffler : 39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb.ft)
Hanger : 19.6 - 24.5 N.m (2.0 - 2.5 kgf.m, 14.5 - 18.1 lb.ft)

5.
Install in the reverse order of removal.
  
.When installing, replace with new gaskets.
Replacing procedures of catalytic converter using clamp
1.
Check that the clamping part of the main muffler assembly is damaged or deformed.

2.
Cut the main muffler as indicated below.

  
Use a pipe cutter or chain pipe cutter to make sure the cutting surface is smooth and even.

3.
Replace the catalytic converter.
Catalytic Converter and Center Muffler
1.
Remove the catalytic converter and center muffler (A).
Tightening torque :
39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)

2.
Install in the reverse order of removal.
  
When installing, replace with new gaskets.
Rear Muffler
1.
Remove the rear muffler (A).
Tightening torque :
39.2 - 58.8 N.m (4.0 - 6.0 kgf.m, 28.9 - 43.4 lb-ft)

2.
Install in the reverse order of removal.
  
When installing, replace with new gaskets.
Lubrication System
Engine Oil. Repair procedures Oil and filter replacement    • Be careful not to damage the parts located under the vehicle (floor under cover, fuel filter, fuel tank and canister) when raising ...

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