Intake and Exhaust System Hyundai Santa Fe III

Scheme 1

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Scheme 3

1. Disconnect the battery "-" terminal.
2. Remove the engine cover.
3. Remove the air duct (A).
4. Remove the air cleaner assembly (A). Disconnect the barometric pressure sensor (BPS) connector (B). Disconnect the breather hose (C). Loosen the clamp (D) and then disconnect the air intake hose from the throttle body. Disconnect the brake vacuum hose (E). Tightening torque Hose clamp bolt: 2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft) Air cleaner assembly 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.

Scheme 4

Scheme 5

1. Open the service cover after pull the clamp of the air cleaner.
2. Replace new an air cleaner element (A).
3. Close the service cover and then fix the clamp.

Scheme 6

Removal and Installation

Note. Mark all wiring and hoses to avoid misconnection.

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Scheme 12

1. Remove the Air cleaner assembly. Refer to «AIR CLEANER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
2. Disconnect the necessary parts like the engine wiring connector and harness clamp around the engine in order to remove the surge tank. Refer to «Surge Tank»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
3. Disconnect the brake vacuum hose (A).
4. Disconnect the PCSV hose (A).
5. Remove the ETC module (A).
6. Disconnect the PCV hose (A), and then remove the surge tank stay (B). Tightening torque: 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)
7. Remove the surge tank (A). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
8. Install in the reverse order of removal.
9. Fill the engine coolant after check coolant level.

Scheme 13

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Scheme 15

1. Remove the surge tank. Refer to «SURGE TANK»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
2. Remove the low pressure fuel line. Refer to «FUEL LINE»(/hyundai/santa-fe/iii-2012-2016/remont/fuel-system/#fuel-delivery-system) .
3. Remove the intake manifold (A). NOTE: Cover the cylinder head intake port with a clean woven stuff or vinyl cover to prevent foreign materials from entering. Make sure the engine and radiator are cool to the touch. Remove radiator cap. Loosen the drain plug and drain the coolant. Tighten the radiator drain plug securely. CAUTION: Drain the engine coolant before removing the intake manifold. Otherwise, engine coolant may enter into the intake port from the vent holes of the cylinder head and this can cause problems in the engine combustion chambers.
4. Install in the reverse order of removal. NOTE: Tighten the intake manifold bolts and nuts, in several passes as below. a ~ h: 1st step order 1 ~ 8: 2nd step order Tightening torque Step 1: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft) Step 2: 26.5 ~ 31.4N.m (2.7~3.2kgf.m, 19.5~23.1lb-ft) Step 3: Repeat 2nd step twice or more. CAUTION: Fill the engine coolant after installing intake manifold and check coolant level.

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Scheme 19

1. Disconnect the LH front and rear heated oxygen sensor (HO2S) connector. Refer to «HEATED OXYGEN SENSOR (HO2S)»(/hyundai/santa-fe/iii-2012-2016/remont/testing-diagnostics/#engine-control-system) .
2. Remove the front muffler. Refer to «MUFFLER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
3. Remove the cooling fan assembly. Refer to «COOLING FAN»(/hyundai/santa-fe/iii-2012-2016/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove oil level gauge assembly. Refer to «OIL LEVEL GAUGE & PIPE»(/hyundai/santa-fe/iii-2012-2016/remont/lubrication-system/#engine-lubrication-system) .
5. Remove the LH exhaust manifold heat protector (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
6. Remove the LH exhaust manifolds stay (A), and then remove the LH exhaust manifold (B) and gasket. Tightening torque Stay bolt: 24.5 ~ 35.3N.m (2.5 ~ 3.6kgf.m, 18.1 ~ 26.0lb-ft) Manifold nuts: 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)
7. Install in the reverse order of removal. NOTE: When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with specified torque in the sequence shown in the illustration.

Scheme 20

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Scheme 22

1. Disconnect the RH front and rear heated oxygen sensor (HO2S) connector. Refer to «HEATED OXYGEN SENSOR (HO2S)»(/hyundai/santa-fe/iii-2012-2016/remont/testing-diagnostics/#engine-control-system) .
2. Remove the surge tank. Refer to «SURGE TANK»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
3. Remove the front muffler. Refer to «MUFFLER»(/hyundai/santa-fe/iii-2012-2016/remont/exhaust/#intake-and-exhaust-system) .
4. Remove the RH exhaust manifold heat protector (A). Tightening torque: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
5. Remove the RH exhaust manifolds stay (A), and then remove the RH exhaust manifold (B) and gasket. Tightening torque Stay bolt: 24.5 ~ 35.3N.m (2.5 ~ 3.6kgf.m, 18.1 ~ 26.0lb-ft) Manifold nuts: 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)
6. Install in the reverse order of removal. NOTE: When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with specified torque in the sequence shown in the illustration.

Scheme 23

1. Disconnect the battery "-" terminal.
2. Remove the engine cover.
3. Disconnect the VIS actuator hose (A).
4. Remove the VIS actuator (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
5. Install in the reverse order of removal.

Scheme 24

1. Disconnect the battery "-" terminal.
2. Remove the engine cover.
3. Disconnect the VIS actuator hose (A).
4. Remove the VIS actuator (B). Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
5. Install in the reverse order of removal.

Scheme 25

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Scheme 27

1. Disconnect the battery "-" terminal.
2. Remove the engine room under cover.
3. Remove the front muffler hanger (A) and bracket (B). Tightening torque Bolts (C): 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft) Nuts (D): 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
4. Remove the front muffler (A). Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
5. Install in the reverse order of removal.

Scheme 28

1. Disconnect the battery "-" terminal.
2. Remove the rubber hanger (A).
3. Remove the center muffler (B). Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
4. Install in the reverse order of removal.

Scheme 29

1. Disconnect the battery "-" terminal.
2. Remove the rubber hanger (A) on the rear muffler.
3. Remove the rear muffler (B). Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)
4. Install in the reverse order of removal. Refer to «FRONT WHEEL TRANSFER ASSEMBLY»(/hyundai/santa-fe/iii-2012-2016/remont/transfer-case/#transfer-assembly) .

See also:
• FUEL LINE
• HEATED OXYGEN SENSOR (HO2S)
• COOLING FAN
• OIL LEVEL GAUGE & PIPE
• FRONT WHEEL TRANSFER ASSEMBLY
• AIR CLEANER