Kia 285102G445 Exhaust Manifold Catalytic Assembly

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For 2006 and earlier 3.5L V6 models, the exhaust manifold catalytic converters are bolted to the undersides of the exhaust manifolds. Begin by raising the vehicle and supporting it securely on jackstands. Unbolt the exhaust pipe from the bottom of the catalytic converter, then disconnect the rubber exhaust pipe supports under the car and carefully lower the front of the pipe as much as possible for access to the catalytic converters. Next, disconnect the oxygen sensors from the catalytic converter, unbolt the converter from the exhaust manifold, and remove it from beneath the vehicle. For 2007 and later models, the primary catalytic converters are integral parts of the exhaust manifolds, and the procedures for exhaust manifold replacement can be found in the relevant sections for four-cylinder and V6 engines.

The catalytic converter is an integral part of the exhaust manifold and cannot be removed from it. To begin removal, disconnect the negative cable from the battery, then remove the air filter housing. Next, disconnect the oxygen sensor electrical connectors and, if replacing the exhaust manifold, remove the sensors. In the engine compartment, remove the upper heat shield from the manifold. Raise the front of the vehicle and support it securely on jackstands. Remove the exhaust manifold support bracket bolts and the bracket if equipped. Apply penetrating oil to the nuts/bolts retaining the manifold, allowing them to soak before removing them. Detach the manifold from the cylinder head, taking care not to damage the oxygen sensors, and discard the gasket. For installation, use a scraper to remove all traces of old gasket material and carbon deposits from the mating surfaces of the manifold and cylinder head. If the gasket shows signs of leaking, check the manifold for warpage with a straightedge. Position a new gasket over the cylinder head studs, noting any directional marks or arrows. Install the manifold and thread the mounting nuts/bolts into place, tightening them from the center out to the specified torque. Reinstall the remaining parts in reverse order of removal, then run the engine and check for exhaust leaks.

Remove the bolts and the heat shield over the exhaust manifold, then take off the exhaust manifold brace if equipped.