Hyundai Cars 2006-2008

Intake Manifold

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Removal & Installation



  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 the negative battery cable.
  8.  
  9. Disconnect AFS (A) and breather hose (B).
  10.  
  11. Remove air cleaner upper cover (D) and intake hose (C).

    Click image to see an enlarged view

    Fig. Disconnect AFS, breather hose, air cleaner upper cover, and intake hose

  12.  
  13. Remove or disconnect the following:

    The RH oxygen sensor connector
     
    The RH injector connector and ignition coil connector
     
    The Purge Control Solenoid Valve (PCSV) connector, Manifold Absolute Pressure (MAP) sensor connector, and PCSV hose
     
    The Electronic Throttle Control (ETC) connector and knock sensor connector
     
    The water hoses from ETC
     
    The PCV hose
     
    The brake vacuum hose
     
    The surge tank stay
     
    The connector bracket from surge tank
     
    The surge tank
     
    The breather Pipe assembly
     
    The LH injector connector.
     

  14.  
  15. Remove intake manifold and gasket
  16.  

To install:

  1. Install intake manifold and new gasket on the cylinder head. Tighten the bolts in the illustrated sequence using the steps below:
    1. Step 1: 3-4 ft. lbs. (4-6 Nm).
    2.  
    3. Step 2: 14-17 ft. lbs. (19-24 Nm).
    4.  
    5. Step 3: Repeat 2nd step twice or more.

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence

    6.  

  2.  
  3. Install the delivery pipe.
  4.  
  5. Connect the LH injector connector.
  6.  
  7. Connect the breather pipe assembly. Tighten to 84-108 inch lbs. (10-12 Nm).
  8.  
  9. Install the surge tank. Tighten long bolt to 84-108 inch lbs. (10-12 Nm); short bolt and nut to 14-17 ft. lbs. (19-24 Nm).

    Click image to see an enlarged view

    Fig. Surge tank and intake manifold components

  10.  
  11. Install the connector bracket on the surge tank. Tighten to 5-8 ft. lbs. (7-11 Nm).
  12.  
  13. Install surge tank stay. Tighten to 20-23 ft. lbs. (27-31 Nm); 14-17 ft. lbs. (19-24 Nm).
  14.  
  15. Connect brake vacuum hose.
  16.  
  17. Connect PCV hose.
  18.  
  19. Connect water hoses to ETC.
  20.  
  21. Install ETC bracket. Tighten to 12-19 ft. lbs. (16-26 Nm).
  22.  
  23. Connect ETC connector and knock sensor connector.
  24.  
  25. Connect PCSV connector, MAP sensor connector and PCSV hose.
  26.  
  27. Connect RH injector connector and ignition coil connector.
  28.  
  29. Connect RH oxygen sensor connector.
  30.  
  31. Install air cleaner upper cover and in take hose.
  32.  
  33. Connect AFS and breather hose.
  34.  

1.6L, 2.0L & 2.4L Engines

Specific to:

Hyundai Accent 2006-2008

Hyundai Elantra 2006-2008

Hyundai Sonata 2006-2008

Hyundai Tiburon 2006-2008

  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:

    The negative battery cable
     
    The engine cover
     
    The accelerator cable (A)
     
    The Throttle Position Sensor (TPS) connector (B) and the MAP sensor connector (F)
     
    The Idle Speed Actuator (ISA) connector (B)
     
    The Positive Crankcase Ventilation (PCV) hose (D) and breather hose (E)

    Click image to see an enlarged view

    Fig. Remove the accelerator cable, the TPS connector, and the MAP sensor connector. Disconnect the ISA connector, the PCV hose, and breather hose-1.6L engine

     

  8.  
  9. Disconnect the fuel injector connectors.
  10.  
  11. Remove the heater hose, Purge Control Solenoid Valve (PCSV), and the brake vacuum hose from the throttle body and intake manifold.
  12.  
  13. Disconnect the PCSV and water temperature sensor connector.
  14.  
  15. Remove the delivery pipe.
  16.  
  17. Remove the intake manifold stay.
  18.  
  19. Remove the intake manifold.

    Click image to see an enlarged view

    Fig. Intake manifold components-1.6L engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Surge tank and intake manifold components-2.4L engine

  20.  

To install:

  1. Install or connect the following:

    The intake manifold. Tighten to 11-15 ft. lbs. (15-20 Nm)
     
    The intake manifold stay. Tighten to 13-18 ft. lbs. (18-25 Nm)
     
    The delivery pipe. Tighten to 14-20 ft. lbs. (19-28 Nm)
     
    The PCSV and water temperature sensor connector
     
    The heater hose, PCSV, and the brake vacuum hose to the throttle body and intake manifold
     
    The fuel injector connectors
     
    The Positive Crankcase Ventilation (PCV) hose (D) and breather hose (E)
     
    The Idle Speed Actuator (ISA) connector (B)
     
    The Throttle Position Sensor (TPS) connector (B) and the MAP sensor connector (F)
     
    The accelerator cable (A)
     
    The engine cover
     
    The negative battery cable
     

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

2.7L Engine

Specific to:

Hyundai Tiburon 2006-2008

  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 the negative battery cable.
  8.  
  9. Remove the engine cover.
  10.  
  11. Remove air cleaner hose.
  12.  
  13. Remove surge tank assembly:
    1. Disconnect the accelerator cable.
    2.  
    3. Disconnect the TPS connector.
    4.  
    5. Disconnect the ISA connector.
    6.  
    7. Disconnect the injector connector.
    8.  
    9. Disconnect the Purge Control Solenoid Valve (PCSV) connector.
    10.  
    11. Disconnect the PCSV hose.
    12.  
    13. Disconnect the brake booster vacuum hose.
    14.  
    15. Disconnect the PCV hose.
    16.  
    17. Disconnect the IAT sensor connector.
    18.  
    19. Remove the surge tank stay.
    20.  
    21. Remove the surge tank assembly.
    22.  

  14.  
  15. Remove the injector assembly.
  16.  
  17. Remove the intake manifold and gasket.

    Click image to see an enlarged view

    Fig. Surge tank and intake manifold components-2.7L engine

  18.  

To install:

  1. Install the intake manifold and gasket. Tighten the bolts in the sequence shown to 14-17 ft. lbs. (19-24 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence-2.7L engine

  2.  
  3. Install the injector assembly.
  4.  
  5. Install the surge tank assembly. Tighten bolts to 14-17 ft. lbs. (19-24 Nm).
    1. Install the surge tank stay. Tighten bolts to 14-17 ft. lbs. (19-24 Nm).
    2.  
    3. Install the ground cable.
    4.  
    5. Connect the IAT sensor connector.
    6.  
    7. Connect the PCV hose.
    8.  
    9. Connect the brake booster vacuum hose.
    10.  
    11. Connect the PCSV hose.
    12.  
    13. Connect the PCSV connector.
    14.  
    15. Connect the injector connector.
    16.  
    17. Connector the ISA connector.
    18.  
    19. Connector the TPS connector.
    20.  
    21. Connector the actuator cable.
    22.  

  6.  
  7. Install the air cleaner hose.
  8.  
  9. Install the engine cover.
  10.  
  11. Install the negative battery cable.
  12.  
  13. Fill the cooling system.
  14.  
  15. Start the engine and check for leaks.
  16.  

3.3L & 3.8L Engines

Specific to:

Hyundai Azera 2006-2008

Hyundai Sonata 2006-2008

  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 the negative battery cable.
  8.  
  9. Disconnect AFS (A) and breather hose (B).
  10.  
  11. Remove air cleaner upper cover (D) and intake hose (C).

    Click image to see an enlarged view

    Fig. Disconnect AFS, breather hose, air cleaner upper cover, and intake hose-3.3L and 3.8L engines

  12.  
  13. Remove or disconnect the following:

    The RH oxygen sensor connector
     
    The RH injector connector and ignition coil connector
     
    The Purge Control Solenoid Valve (PCSV) connector, Manifold Absolute Pressure (MAP) sensor connector, and PCSV hose
     
    The Electronic Throttle Control (ETC) connector and knock sensor connector
     
    The water hoses from ETC
     
    The PCV hose
     
    The brake vacuum hose
     
    The surge tank stay
     
    The connector bracket from surge tank
     
    The surge tank
     
    The breather Pipe assembly
     
    The LH injector connector.
     

  14.  
  15. Remove intake manifold and gasket
  16.  

To install:

  1. Install intake manifold and new gasket on the cylinder head. Tighten the bolts in the illustrated sequence using the steps below:
    1. Step 1: 3-4 ft. lbs. (4-6 Nm).
    2.  
    3. Step 2: 14-17 ft. lbs. (19-24 Nm).
    4.  
    5. Step 3: Repeat 2nd step twice.

      Click image to see an enlarged view

      Fig. Intake manifold torque sequence-3.3L and 3.8L engines



      Click image to see an enlarged view

      Fig. Surge tank and intake manifold components-3.3L and 3.8L engines

    6.  

  2.  
  3. Install the delivery pipe.
  4.  
  5. Connect the LH injector connector.
  6.  
  7. Connect the breather pipe assembly. Tighten to 84-108 inch lbs. (10-12 Nm).
  8.  
  9. Install the surge tank. Tighten long bolt to 84-108 inch lbs. (10-12 Nm); short bolt and nut to 14-17 ft. lbs. (19-24 Nm).
  10.  
  11. Install the connector bracket on the surge tank. Tighten to 5-8 ft. lbs. (7-11 Nm).
  12.  
  13. Install surge tank stay. Tighten to 20-23 ft. lbs. (27-31 Nm); 14-17 ft. lbs. (19-24 Nm).
  14.  
  15. Connect brake vacuum hose.
  16.  
  17. Connect PCV hose.
  18.  
  19. Connect water hoses to ETC.
  20.  
  21. Install ETC bracket. Tighten to 12-19 ft. lbs. (16-26 Nm).
  22.  
  23. Connect ETC connector and knock sensor connector.
  24.  
  25. Connect PCSV connector, MAP sensor connector and PCSV hose.
  26.  
  27. Connect RH injector connector and ignition coil connector.
  28.  
  29. Connect RH oxygen sensor connector.
  30.  
  31. Install air cleaner upper cover and in take hose.
  32.  
  33. Connect AFS and breather hose.
  34.  

 
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