Hyundai Car 1999-05

Intake Manifold

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Removal & Installation





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Fig. Surge tank and intake manifold components-1.5L engine



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Fig. Surge tank and intake manifold components-Sonata 2.0L and 2.4L engines



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Fig. Surge tank and intake manifold components-Elantra and Tiburon 2.0L engine



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Fig. Surge tank and intake manifold components-1.5L engine



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Fig. Surge tank and intake manifold components-1.8L engines



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Fig. Surge tank and intake manifold components-Sonata 2.0L and 2.4L engines



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Fig. Surge tank and intake manifold components-Elantra and Tiburon 2.0L engine



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Fig. Surge tank and intake manifold components-1.5L engine



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Fig. Surge tank and intake manifold components-1.8L engines



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Fig. Surge tank and intake manifold components-Sonata 2.0L and 2.4L engines



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Fig. Surge tank and intake manifold components-Elantra and Tiburon 2.0L engine

4-Cylinder Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness connectors
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Brake booster vacuum line
     
    Intake manifold vacuum hoses
     
    Fuel lines
     
    Surge tank
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Heater hose
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Spark plug wires
     
    Thermostat housing
     
    Distributor, if equipped
     
    Ignition coil
     
    Intake manifold bracket
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm), starting from the center and working outwards
     
    Intake manifold bracket and torque the bolts to 13-18 ft. lbs. (18-25 Nm)
     
    Ignition coil
     
    Distributor, if equipped
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Spark plug wires
     
    ECT sensor connector
     
    Heater hose
     
    Fuel supply manifold
     
    Fuel injector connectors
     
    Surge tank using a new gasket and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
     
    Fuel lines
     
    Intake manifold vacuum hoses
     
    Brake booster vacuum line
     
    PCV valve and hose
     
    Throttle body
     
    Engine control wiring harness connectors
     
    Upper radiator hose
     
    Accelerator cable
     
    Air intake hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness connectors
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Brake booster vacuum line
     
    Intake manifold vacuum hoses
     
    Fuel lines
     
    Surge tank
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Heater hose
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Spark plug wires
     
    Thermostat housing
     
    Distributor, if equipped
     
    Ignition coil
     
    Intake manifold bracket
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm), starting from the center and working outwards
     
    Intake manifold bracket and torque the bolts to 13-18 ft. lbs. (18-25 Nm)
     
    Ignition coil
     
    Distributor, if equipped
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Spark plug wires
     
    ECT sensor connector
     
    Heater hose
     
    Fuel supply manifold
     
    Fuel injector connectors
     
    Surge tank using a new gasket and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
     
    Fuel lines
     
    Intake manifold vacuum hoses
     
    Brake booster vacuum line
     
    PCV valve and hose
     
    Throttle body
     
    Engine control wiring harness connectors
     
    Upper radiator hose
     
    Accelerator cable
     
    Air intake hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness connectors
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Brake booster vacuum line
     
    Intake manifold vacuum hoses
     
    Fuel lines
     
    Surge tank
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Heater hose
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Spark plug wires
     
    Thermostat housing
     
    Distributor, if equipped
     
    Ignition coil
     
    Intake manifold bracket
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm), starting from the center and working outwards
     
    Intake manifold bracket and torque the bolts to 13-18 ft. lbs. (18-25 Nm)
     
    Ignition coil
     
    Distributor, if equipped
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Spark plug wires
     
    ECT sensor connector
     
    Heater hose
     
    Fuel supply manifold
     
    Fuel injector connectors
     
    Surge tank using a new gasket and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
     
    Fuel lines
     
    Intake manifold vacuum hoses
     
    Brake booster vacuum line
     
    PCV valve and hose
     
    Throttle body
     
    Engine control wiring harness connectors
     
    Upper radiator hose
     
    Accelerator cable
     
    Air intake hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

V6 Engine


Click image to see an enlarged view

Fig. Surge tank and intake manifold components-XG 300 and XG 350

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Intake manifold vacuum hoses
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Surge tank
     
    Fuel lines
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Thermostat housing
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm) for 3.0L and 3.5L engines or to 14-15 ft. lbs. (15-20 Nm) for 2.5L and 2.7L engines starting from the center and working outwards
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Fuel supply manifold and torque the bolts to 84-108 inch lbs. (10-13 Nm)
     
    Fuel injector connectors
     
    Fuel lines
     
    Surge tank and torque the bolts to 11-14 ft. lbs. (15-20 Nm)
     
    EGR pipe
     
    Intake manifold vacuum hoses
     
    PCV valve and hose
     

  2.  


NOTE
One throttle body bolt is shorter than the rest. This bolt is installed in the upper left hole when viewed from the front of the throttle body.



Throttle body and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
 
Engine control wiring harness
 
Upper radiator hose
 
Accelerator cable
 
Air intake hose
 
Negative battery cable
 

  1. Fill the cooling system.
  2.  
  3. Start the engine and check for leaks.
  4.  



Click image to see an enlarged view

Fig. Surge tank and intake manifold components-XG 300

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Intake manifold vacuum hoses
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Surge tank
     
    Fuel lines
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Thermostat housing
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    One throttle body bolt is shorter than the rest. This bolt is installed in the upper left hole when viewed from the front of the throttle body.



    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm) for 3.0L engines or to 14-15 ft. lbs. (15-20 Nm) for 2.5L engines starting from the center and working outwards
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Fuel supply manifold and torque the bolts to 84-108 inch lbs. (10-13 Nm)
     
    Fuel injector connectors
     
    Fuel lines
     
    Surge tank and torque the bolts to 11-14 ft. lbs. (15-20 Nm)
     
    EGR pipe
     
    Intake manifold vacuum hoses
     
    PCV valve and hose
     



    Throttle body and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
     
    Engine control wiring harness
     
    Upper radiator hose
     
    Accelerator cable
     
    Air intake hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  



Click image to see an enlarged view

Fig. Surge tank and intake manifold components-XG 300

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake hose
     
    Accelerator cable
     
    Upper radiator hose
     
    Engine control wiring harness
     
    Throttle body
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Intake manifold vacuum hoses
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Surge tank
     
    Fuel lines
     
    Fuel injector connectors
     
    Fuel supply manifold
     
    Thermostat housing
     
    Intake manifold and discard the gasket
     

  8.  

To install:

  1. Install or connect the following:
    NOTE
    One throttle body bolt is shorter than the rest. This bolt is installed in the upper left hole when viewed from the front of the throttle body.



    Intake manifold using a new gasket and torque the nuts to 11-14 ft. lbs. (15-20 Nm) for 3.0L engines or to 14-15 ft. lbs. (15-20 Nm) for 2.5L engines starting from the center and working outwards
     
    Thermostat housing and torque the bolts to 12-14 ft. lbs. (17-20 Nm)
     
    Fuel supply manifold and torque the bolts to 84-108 inch lbs. (10-13 Nm)
     
    Fuel injector connectors
     
    Fuel lines
     
    Surge tank and torque the bolts to 11-14 ft. lbs. (15-20 Nm)
     
    EGR pipe
     
    Intake manifold vacuum hoses
     
    PCV valve and hose
     



    Throttle body and torque the bolts to 11-16 ft. lbs. (15-22 Nm)
     
    Engine control wiring harness
     
    Upper radiator hose
     
    Accelerator cable
     
    Air intake hose
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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