AutoZone 1987 Hyundai Excel 1.5L 2BL SOHC 4cyl | Repair Guides | Engine And Engine Overhaul | Engine Mechanical | Intake Manifold | AutoZone.com

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    1987 Hyundai Excel 1.5L 2BL SOHC 4cyl

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    GM Cadillac Deville_Fleetwood_ELD_Seville 1990-1998

    Intake Manifold

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    REMOVAL & INSTALLATION



    3.0L Engine

    This vehicle uses a sequential multiport fuel injected engine. Fuel injector connectors must be positioned onto their appropriate fuel injector or engine performance and exhaust emissions may be seriously affected. Fuel injector connectors are numbered to match their cylinders.

    1. Remove the intake plenum.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Remove the fuel supply and fuel return hose from the fuel rail.
    6.  
    7. Fuel injector electrical harness connector.
    8.  
    9. Remove the intake manifold bolts and the intake manifold.
    10.  


    NOTE
    Mask off the ports to the intake manifold spacer. If foreign objects enter the engine, severe damage may result.

    Clean the intake manifold sealing surfaces with a non-abrasive tool or solvent.

    Do not damage machined aluminum surfaces or improper sealing may occur.



    Click image to see an enlarged view

    Fig. Location of the guide pins for the intake plenum-3.0L engine



    Click image to see an enlarged view

    Fig. Intake plenum-to-intake manifold mounting



    Click image to see an enlarged view

    Fig. The intake manifold bolt locations

    To install:

    1. Remove the masking from the intake ports.
    2.  
    3. Install the intake manifold, and tighten the intake bolts to 15 ft. lbs. (20 Nm), rotating the tightening sequence.
    4.  
    5. Reconnect the fuel injector electrical harness connector.
    6.  
    7. Couple the fuel supply and fuel return hose,. Tighten the connection to 11 ft. lbs. (15 Nm).
    8.  


    NOTE
    Counterhold the connections to prevent damage to the fuel rail.

    1. Install the intake plenum.
    2.  
    3. Connect the negative battery cable.
    4.  

    4.5L and 4.9L Engines
    1. Disconnect the negative battery cable.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain and recycle the engine coolant.
    6.  
    7. Remove the coolant reservoir. Disconnect the upper radiator hose from the thermostat housing.
    8.  
    9. Remove the air cleaner and the serpentine drive belt. Label and disconnect the spark plug wires from the spark plugs.
    10.  
    11. Remove the cross brace.
    12.  
    13. Remove the power steering pump and tensioner bracket assembly and reposition them toward the front of engine.
    14.  
    15. Remove the alternator and bracket.
    16.  
    17. Remove the cruise control servo with the bracket and the throttle valve cables and position them aside.
    18.  
    19. Detach the wire connections and reposition:
      1. Distributor
      2.  
      3. Oil pressure switch
      4.  
      5. Coolant temperature sensor
      6.  
      7. EGR solenoid
      8.  
      9. ISC motor
      10.  
      11. Throttle position switch
      12.  
      13. If equipped, electric EFE grid
      14.  
      15. Injectors
      16.  
      17. MAT sensor
      18.  

    20.  
    21. If equipped, disconnect the MAP hoses. Remove the upper radiator hose and the heater hose. Remove the air-conditioning hose bracket.
    22.  
    23. Disconnect the spark plug wire protectors and reposition the cap.
    24.  
    25. Mark the distributor rotor position and remove the distributor.
    26.  


    NOTE
    Do not crank or in any other way rotate the crankshaft with the distributor removed.

    1. Disconnect the fuel and vacuum lines from the throttle body. Disconnect the vacuum supply solenoid and lines.
    2.  
    3. Remove the valve covers. Remove the rocker arms and pushrods.
    4.  


    NOTE
    Pushrods should be marked or retained in sequence so they may be reinstalled in their original positions.

    1. Remove the right front and rear lift brackets. Remove the intake manifold bolts and remove the intake manifold, gaskets, and seals. Discard the gaskets and seals.
    2.  
    3. Clean the sealing surfaces of the intake manifold, cylinder head, and cylinder block.
    4.  

    To install:

    1. Install new end seals. Use RTV at the 4 corners where the end seals will meet the side gaskets.
    2.  
    3. Install the new intake to cylinder head gaskets. Use RTV at the 4 corners of end seals.
    4.  
    5. Tighten the intake manifold bolts by performing the following:
      1. Tighten bolts 1, 2, 3, and 4, in sequence, to 8 ft. lbs. (12 Nm).
      2.  
      3. Tighten bolts 5 through 16, in sequence, to 8 ft. lbs. (12 Nm).
      4.  
      5. Retighten all bolts, in sequence, to 12 ft. lbs. (16 Nm).
      6.  

    6.  
    7. Install the pushrods and rocker arm assemblies.
    8.  
    9. Install the valve and rocker arm assemblies.
    10.  
    11. Install the valve covers. Install the vacuum supply solenoid and lines. Install the fuel and vacuum lines to the throttle body.
    12.  
    13. Install the distributor in its original position. Install the distributor cap and wire protectors.
    14.  
    15. Install the air-conditioning hose bracket.
    16.  
    17. Install the upper radiator hose and heater hose. If equipped, connect the MAP hoses.
    18.  
    19. Connect following wire connectors:
      1. Distributor
      2.  
      3. Oil pressure switch
      4.  
      5. Coolant temperature sensor
      6.  
      7. EGR solenoid
      8.  
      9. ISC motor
      10.  
      11. Throttle position switch
      12.  
      13. If equipped, the electric EFE grid
      14.  
      15. Injectors
      16.  
      17. MAT sensor
      18.  

    20.  
    21. Install cruise control servo and throttle valve cables.
    22.  
    23. Install the alternator bracket and alternator.
    24.  
    25. Install the power steering pump and tensioner assembly. Install the power steering line brace to the right side cylinder head.
    26.  
    27. Install the serpentine drive belt. Install the coolant reservoir.
    28.  
    29. Install the cross brace.
    30.  
    31. Fill the cooling system.
    32.  
    33. Install the air cleaner assembly.
    34.  
    35. Connect the negative battery cable.
    36.  
    37. Start the engine and check for coolant, oil, or fuel leaks. Allow the engine to come to normal operating temperature and recheck for leaks.
    38.  



    Click image to see an enlarged view

    Fig. Intake manifold and gaskets-4.5L and 4.9L engines



    Click image to see an enlarged view

    Fig. Intake manifold bolt tightening sequence-4.5L and 4.9L engines

    4.6L Engine


    Click image to see an enlarged view

    Fig. Remove the appearance cover to gain access to the intake manifold



    Click image to see an enlarged view

    Fig. Detach the vacuum connection from the throttle body



    Click image to see an enlarged view

    Fig. Detach the throttle cable from the throttle body



    Click image to see an enlarged view

    Fig. Remove the fuel line from the intake manifold



    Click image to see an enlarged view

    Fig. Remove the intake manifold retaining bolts and . . .



    Click image to see an enlarged view

    Fig. . . . lift the intake from the engine



    Click image to see an enlarged view

    Fig. Thoroughly clean the intake manifold mounting surfaces

    1. Disconnect the negative battery cable.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain and recycle the engine coolant.
    6.  
    7. Remove the intake duct from the throttle body.
    8.  
    9. Disconnect the coolant hoses at the throttle body.
    10.  
    11. Detach the 2 electrical connectors at the intake manifold. Also the TP sensor, ISC motor, EVAP solenoid and cruise control servo.
    12.  
    13. Disconnect the vacuum hoses at the brake vacuum booster, and the fuel pipe bundle to the body.
    14.  
    15. Disconnect the PCV valve at the intake manifold.
    16.  
    17. Disconnect the accelerator cable at the throttle body and position it out of the way.
    18.  
    19. Detach the fuel pipe quick connects at the fuel pipe bundle in the engine compartment.
    20.  
    21. Remove the EVAP solenoid bracket at the rear cam cover.
    22.  
    23. Reposition the transaxle range control cable away from the cruise control servo.
    24.  
    25. Remove the 4 intake manifold bolts and lift the intake manifold with the throttle body out of the engine compartment.
    26.  
    27. Remove the intake manifold seals and spacers at the cylinder heads.
    28.  
    29. Remove the fuel pipe retainer at the ISC bracket.
    30.  
    31. Remove the 4 throttle body bolts and remove the throttle body from the intake manifold.
    32.  

    To install:

    1. It is important to use a NEW throttle body seal on the throttle body coated with petroleum jelly.
    2.  


    WARNING
    Do not reuse the old throttle body seal because it may not seat properly. Do not use any type of silicone lubricant on the seal or damage could result.

    1. Install the throttle body with the 4 bolts to the intake manifold and tighten to 106 inch lbs. (12 Nm).
    2.  
    3. Install the fuel pipe retainer at the ISC bracket.
    4.  
    5. Install the intake manifold seals and spacers at the cylinder heads.
    6.  
    7. Install the intake manifold and throttle body with the 4 intake manifold bolts and tighten to the torque and sequence in the illustration.
    8.  
    9. Connect the coolant hoses at the throttle body and coolant reservoir and add coolant as necessary.
    10.  
    11. Position the transaxle range control cable away at the cruise control servo bracket.
    12.  
    13. Install the EVAP solenoid bracket at the rear cam cover.
    14.  
    15. Connect the fuel pipe quick connects at the fuel pipe bundle in the engine compartment.
    16.  
    17. Connect the accelerator cable at the throttle body.
    18.  
    19. Connect the vacuum hoses at the brake vacuum booster, fuel pipe bundle and to body.
    20.  
    21. Connect the PCV valve at the intake manifold.
    22.  
    23. Connect the 2 electrical connectors at the intake manifold. Also the TP sensor, ISC motor, EVAP solenoid and cruise control servo.
    24.  
    25. Install the intake duct to the throttle body.
    26.  
    27. Connect the negative battery cable.
    28.  



    Click image to see an enlarged view

    Fig. Intake manifold installation-4.6L Northstar engine



    Click image to see an enlarged view

    Fig. Intake manifold seals-4.6L Northstar engine



    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-4.6L Northstar engine

     
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