Hyundai Tucson: Catalytic converter - Components

1. Warm up catalytic converter
2. Warm up catalytic converter gasket
3. Warm up catalytic converter upper stay bracket
4. Warm up catalytic converter lower stay bracket
5. Cylinder head heat peotector
6. Oil feed pipe
7. Torbo charhe water outlet hose & pipe B
8. Torbo charhe water outlet pipe A
9. Torbo charhe water inlet pipe
10. Exhaust manifold heat protector A
11. Exhaust manifold & Turbo charger
12. Exhaust manifold & Turbo charger gasket
13. Exhaust manifold heat protector B
14. Electric waste gate actuator (EWGA)
15. Oil drain pipe gasket
16. Oil drain pipe

Catalytic converter - Removal and Installation

1. Disconnect the negative battery terminal.
2. Remove the engine cover.

(Refer to Engine and Transaxle Assembly - "Engine Cover")

3. Remove the engine room under cover.

(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

4. Drain the coolant.

(Refer to Cooling System - "Coolant")

5. Remove the front muffler.

(Refer to Intake And Exhaust System - "Muffler")

6. Install the jack to the edge of oil pan.

WARNING

Insert the rubber block between jack and oil pan.

7. Remove the engine mounting support bracket (A).

Tightening torque : Bolt and Nut (B, C) : 88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb-ft)

8. Remove the connector bracket (A) after disconnecting the connectors and loosening the mounting bolt

9. Disconnect the coolant reservoir tank water hose (A).

10. Disconnect the engine ground cable (A).

Tightening torque : 6.8 - 9.8 N.m (0.7 - 1.0 kgf.m, 5.1 - 7.2 lb-ft)

11. Remove the warm up catalytic converter(WCC) upper stay beacket (A).

Tightening torque : 39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb-ft)

WARNING

When installing, tighten the bolts with specified torque in the sequence shown.

12. Remove the warm up catalytic converter(WCC) lower stay beacket (A).

Tightening torque : 49.1 - 54.0 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

WARNING

When installing, tighten the bolts with specified torque in the sequence shown.

13. Loosen the EGR cooler mounting bolt and nut (A).

Tightening torque : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

WARNING

When installing, replace with a new gasket.

14. Remove the warm up catalytic converter (WCC) (A).

Tightening torque : 35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

WARNING

When installing, replace with a new gasket.

15. Remove the air duct and air cleaner assembly.

(Refer to Intake and Exhaust System - "Air Cleaner")

16. Remove the battery and battery tray.

(Refer to Engine Electrical System - "Battery")

17. Disconnect the wiring protector (A) and extension wiring connector (B).

18. Disconnect the turbo charger intake hose B (A).

19. Disconnect the intercooler inlet hose (A).

Tightening torque : Clamp bolt: 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

WARNING

Insert the hose until it reaches the end of stopper.

220. Remove the resonator assembly and intercooler pipe (A).

Tightening torque : Mounting bolt : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

WARNING

When disconnecting the resonator assembly, pull the quick connector clamp in the direction of the arrow as below.

• When installing the intercooler inlet hose, Match the alignment marks.
• Insert the hose until it reaches the end of stopper.

21. Remove the extension wiring (A) after disconnecting the connectors.

22. Disconnecting the breather hose (A).

23. Remove the differential pressure sensor (A) after disconnecting the hoses and loosening the mounting bolts.

24. Disconnect the EGR hose (A).

25. Remove the turbo charger inlet pipe (A).

26. Disconnect the water outlet hoses (A), and then remove the turbo charger water outle pipe and hose (B).

Tightening torque :

Bracket bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Eye bolt : 34.3 - 39.2 N.m (3.5 - 4.0 kgf.m, 25.3 - 28.9 lb-ft)

WARNING

• When installing, replace with a new eye bolt gasket.
• When installing, provisionally tighten the bracket bolts and eye bolt, and then tighten the eyebolt with specified torque.

Temporarily tighten the eye bolt → Temporarily tighten the bracket mounting bolts → Tighten the specified torpue with the eye bolt → Tighten the specified torque with the bracket mounting bolts

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

Tightening torque : Eye bolt : 34.3 - 39.2 N.m (3.5 - 4.0 kgf.m, 25.3 - 28.9 lb-ft)

WARNING

When installing, replace with a new eye bolt gasket.

28. Remove the turbo charger oil drain pipe (A).

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

WARNING

When installing, replace with a new gasket.

29. Remove the turbo charger heat protect (A).

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

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

Tightening torque :

Oil feed eye bolt : 16.7 - 21.6 N.m (1.7 - 2.2 kgf.m, 12.3 - 15.9 lb-ft)

Oil feed pipe : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

Oil feed pipe bracket bolt : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

WARNING

• If the oil feed pipe is damaged, engine oil is not supplied sufficiently to the turbocharger then it may damage the turbocharger. Be care full the oil feed pipe not to damage.(bent, crushed, torn or cracked).
• When installing, replace with a new gasket.
• When installing the oil feed pipe, install in the following order.

Temporarily tighten the eye bolt & pipe bolts → Temporarily tighten the bracket mounting bolts → Tighten the specified torpue with the eye bolt & pipe bolts → Tighten the specified torque with the bracket mounting bolts

31. Remove the turbo charger heat protector (A).

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

32. Remove the exhaust manifold & turbo charger (A).

Tightening torque : 49.1 - 54.0 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb-ft)

WARNING

When installing the exhaust manifold tighten the nuts with specified torque in the sequence shown.

33. Remove the exhaust manifold & turbo charger gasket (A).

WARNING

When installing, replace with a new gasket.

34. Remove the electric WGT control actuator rod C- ring (A).

35. Remove the electric WGT control actuator (A) after loosening the mounting bolts.

36. Install in the reverse order of removal.

WARNING

Adjust the EWGA rod.

(Refer to Engine Control / Fuel System - "Electric WGT Control Actuator")

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