Hyundai Coupes/Sedans 1986-1993 Repair Guide

Intake Manifold

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REMOVAL & INSTALLATION



1986-89 1468cc Engine

See Figure 1

  1. Disconnect the negative battery cable. Remove the air cleaner assembly.
  2.  
  3. Disconnect the fuel line and the EGR lines, if equipped with EGR. Tag and disconnect all vacuum hoses.
  4.  
  5. Disconnect the throttle positioner and fuel cut-off solenoid wires.
  6.  
  7. Disconnect the throttle linkage.
  8.  
  9. If equipped with an automatic transaxle, disconnect the shift cable linkage.
  10.  
  11. Disconnect the power brake booster vacuum line.
  12.  
  13. Drain the cooling system.
  14.  
  15. Disconnect the choke water hose at the manifold.
  16.  
  17. Remove the heater and water outlet hoses, disconnect the water temperature sending unit.
  18.  
  19. Remove the mounting nuts that hold the manifold to the cylinder head. Remove the intake manifold.
  20.  

To install:
  1. Clean all mounting surfaces. Before installing the manifold, coat both sides of a new gasket with a gasket sealer.
  2.  

If equipped with jet air system, take care not to get any sealer into the jet air intake passage.

  1. Install the intake manifold assembly to the engine block.
  2.  
  3. Reconnect the heater and water outlet hoses. Connect the water temperature sending unit.
  4.  
  5. Connect the brake booster vacuum line. Connect the choke hose at the manifold.
  6.  
  7. Connect the throttle and shift cable linkages, the fuel lines and all vacuum hoses. Install the air cleaner.
  8.  
  9. Refill the engine with coolant. Connect the negative battery cable.
  10.  



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Fig. Fig. 1: Intake manifold sealant application points-1986-89 1468cc engine

1990-93 1468cc and 1495cc Engines

See Figure 2, 3, 4 and 5



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Fig. Fig. 2: Intake manifold and related components-1990-93 1468cc fuel injected engine



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Fig. Fig. 3: Intake manifold and related components-1495cc engine

  1. Disconnect the air intake hose from the throttle body. Position the hose off to the side and out of the way.
  2.  
  3. Disconnect the accelerator cable from the throttle lever. To do this loosen the two cable adjusting bracket bolts so that there is enough play in the cable to disengage the cable end from the throttle lever. Move the cable out of the way.
  4.  
  5. Disconnect the water hose from the water outlet fitting.
  6.  
  7. Remove the throttle body and gasket.
  8.  
  9. Disconnect the PCV hose from the rocker cover and disconnect the brake vacuum hoses.
  10.  
  11. Disconnect all vacuum hoses from their respective connections on the intake manifold. Make sure that you label them to avoid confusion during installation. On turbocharged engines, disconnect the air intake pipe from the turbocharger.
  12.  
  13. Relieve the fuel system pressure, then disconnect the high pressure fuel hose connection from the fuel delivery pipe. Cover the connection joint with a rag to absorb the excess fuel.
  14.  
  15. Unbolt and remove the air intake surge tank (and gasket) from the intake manifold.
  16.  
  17. Disconnect the fuel injector harness connectors.
  18.  
  19. Unbolt and remove the fuel delivery pipe (with pressure regulator) from the intake manifold. Take care not to drop the injectors when removing the delivery pipe.
  20.  
  21. Disconnect the wiring harness that runs between the water temperature gauge and the water temperature sensor assembly.
  22.  
  23. Remove the water outlet fitting and gasket from the intake manifold. Remove the thermostat.
  24.  
  25. Disconnect the spark plug wires from the distributor cap. Make sure that you label them first.
  26.  
  27. Remove the distributor and the ignition coil.
  28.  
  29. Remove the intake manifold stay.
  30.  
  31. Remove the intake manifold retaining nuts. Rock the intake manifold back and forth to separate it from the cylinder head. Remove the intake manifold gasket.
  32.  
  33. Clean all the intake manifold and cylinder head gasket surfaces making sure that all existing gasket material is removed. Do the same for the surge tank and all other gasket mating surfaces. Inspect the intake manifold and surge tank for cracks and check the coolant passages for restrictions. Replace all gaskets.
  34.  

To install:
  1. Install the intake manifold gasket. Position the intake manifold to the cylinder head studs and lower it onto the gasket. Install the intake manifold retaining nuts and torque them to 11-14 ft. lbs, starting from the center and working outwards.
  2.  
  3. Install the intake manifold stay and torque the retaining bolts to 13-18 ft. lbs.
  4.  
  5. Install the ignition coil, distributor, and spark plug wires.
  6.  
  7. Install the thermostat into the intake manifold.
  8.  
  9. Install the water outlet fitting with a new gasket. Torque the retaining bolts to 12-14 ft. lbs.
  10.  
  11. Connect the wiring harness that runs between the temperature sensor and temperature gauge.
  12.  
  13. Install the fuel delivery pipe onto the intake manifold. Torque the retaining bolts to 7-9 ft. lbs.
  14.  
  15. Connect the fuel injector harness connectors.
  16.  
  17. Place the surge tank and gasket onto the intake manifold. Install the retaining bolts and torque them to 11-14 ft. lbs.
  18.  
  19. Connect the high pressure hose to the fuel delivery pipe.
  20.  
  21. Connect the intake manifold, brake and PCV vacuum hoses.
  22.  
  23. Install the throttle body with a new gasket. Torque the throttle body bolts to 7-9 ft. lbs.
  24.  
  25. Connect the water hose to the outlet fitting.
  26.  
  27. Connect the accelerator cable to the throttle lever and tighten the cable bracket adjusting bolts.
  28.  
  29. Connect the air intake hose to the throttle body.
  30.  
  31. Start the engine and check/adjust the ignition timing and the idle speed. Check for fuel and coolant leaks.
  32.  

2351cc Engine


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Fig. Fig. 4: Intake manifold and related components-2351cc engine

  1. Disconnect the negative battery cable. Remove the air cleaner assembly.
  2.  
  3. Release fuel system pressure. Disconnect the fuel line and the EGR lines. Tag and disconnect all vacuum hoses.
  4.  
  5. Disconnect the throttle positioner and fuel cut-off solenoid wires.
  6.  
  7. Disconnect the throttle linkage. If equipped with automatic transaxle, disconnect the shift cable linkage.
  8.  
  9. Remove the heater and water outlet hoses and disconnect the water temperature sending unit. Disconnect the oxygen sensor connector, power transistor connector, ISC connector, ignition coil connector, etc. and the distributor.
  10.  
  11. Remove the mounting nuts that hold the manifold to the cylinder head. Remove the intake manifold lower and upper sections with injector assembly as a unit.
  12.  
  13. Clean all mounting surfaces. Before installing the manifold, coat both sides with a gasket sealer.
  14.  

To install:
  1. Clean all mounting surfaces. Before installing the manifold, coat both sides of a new gasket with a gasket sealer.
  2.  

If equipped with jet air system, take care not to get any sealer into the jet air intake passage.

  1. Install the intake manifold lower and upper sections with injector assembly as a unit. Install the mounting nuts that hold the manifold to the cylinder head.
  2.  
  3. Install the heater and water outlet hoses, disconnect the water temperature sending unit. Connect the oxygen sensor connector, power transistor connector, ISC connector, ignition coil connector, etc. and the distributor.
  4.  
  5. Connect the throttle linkage. If equipped with automatic transaxle, connect the shift cable linkage.
  6.  
  7. Connect the throttle positioner and fuel cut-off solenoid wires.
  8.  
  9. Connect the fuel line and the EGR lines. Connect all vacuum hoses.
  10.  
  11. Refill the engine with coolant. Connect the negative battery cable.
  12.  

1596cc, 1796cc and 1997cc Engines


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Fig. Fig. 5: Intake manifold and related components-1596cc, 1796cc and 1997cc engines

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect battery negative cable and drain the cooling system.
  4.  
  5. Disconnect the accelerator cable, breather hose and air intake hose.
  6.  
  7. Disconnect the upper radiator hose, heater hose and water bypass hose.
  8.  
  9. Remove all vacuum hoses and pipes as necessary, including the brake booster vacuum line.
  10.  
  11. Disconnect the high pressure fuel line, fuel return hose and remove throttle control cable brackets.
  12.  
  13. Tag and disconnect the electrical connectors from the oxygen sensor, coolant temperature sensor, thermo- switch, idle speed control connection, spark plug wires, etc. that may interfere with the manifold removal procedure.
  14.  
  15. Remove the fuel delivery pipe, fuel injectors, pressure regulator and insulators from the engine. Be careful not to drop the injectors when removing the assembly from the engine.
  16.  
  17. Disconnect the water hose connections at the throttle body, water inlet, and heater assembly.
  18.  
  19. If the thermostat housing is preventing removal of the intake manifold, remove it.
  20.  
  21. Disconnect the vacuum connection at the power brake booster and the PCV valve, if still connected.
  22.  
  23. Remove the intake manifold mounting bolts and remove the intake manifold assembly.
  24.  

To install:
  1. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. Check both surfaces for cracks or other damage. Check the intake manifold water passages for clogging and clean if necessary.
  2.  
  3. Install a new intake manifold gasket to the head and install the manifold. Torque the manifold in a criss-cross pattern, starting from the inside and working outwards to 11-14 ft. lbs. (15-19 Nm).
  4.  
  5. Install the fuel delivery pipe, injectors and pressure regulator from the engine. Torque the retaining bolts to 7-9 ft. lbs. (10-13 Nm).
  6.  
  7. Install the thermostat housing, intake manifold brace bracket, distributor and throttle body stay bracket.
  8.  
  9. Connect or install all hoses, cables and electrical connectors that were removed or disconnected during the removal procedure.
  10.  
  11. Fill the system with coolant.
  12.  
  13. Connect the negative battery cable, run the vehicle until the thermostat opens, then fill the radiator completely.
  14.  
  15. Adjust the accelerator cable. Check and adjust the idle speed as required.
  16.  
  17. Once the vehicle has cooled, recheck the coolant level.
  18.  

2972cc Engine

See Figures 6 and 7



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Fig. Fig. 6: Upper intake manifold and surge tank components-2972cc engine



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Fig. Fig. 7: Intake manifold and related components-2972cc engine

  1. Disconnect the negative battery cable. Relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the throttle body to air cleaner hose.
  6.  
  7. Remove the throttle body and transaxle kickdown linkage.
  8.  
  9. Remove the AIS motor and TPS wiring connectors from the throttle body.
  10.  
  11. Remove and label the vacuum hose harness from the throttle body.
  12.  
  13. From the air intake plenum, remove the PCV and brake booster hoses and the EGR tube flange.
  14.  
  15. Disconnect and label the charge and temperature sensor wiring at the intake manifold.
  16.  
  17. Remove the vacuum connections from the air intake plenum vacuum connector.
  18.  
  19. Remove the fuel hoses from the fuel rail.
  20.  
  21. Remove the air intake plenum mounting bolts and the plenum.
  22.  
  23. Remove the vacuum hoses from the fuel rail and pressure regulator.
  24.  
  25. Disconnect the fuel injector wiring harness from the engine wiring harness.
  26.  
  27. Remove the fuel pressure regulator mounting bolts and the regulator from the fuel rail.
  28.  
  29. Remove the fuel rail mounting bolts and the fuel rail from the intake manifold.
  30.  
  31. Separate the radiator hose from the thermostat housing and heater hoses from the heater pipe.
  32.  
  33. Remove the intake manifold mounting bolts and the manifold from the engine.
  34.  
  35. Clean the gasket mounting surfaces on the engine and intake manifold.
  36.  

To install:
  1. Using new gaskets, position the intake manifold on the engine and install the mounting nuts and washers.
  2.  
  3. Torque the mounting nuts gradually and evenly, in sequence, to 15 ft. lbs. (20 Nm).
  4.  
  5. Make sure the injector holes are clean. Lubricate the injector O-rings with a drop of clean engine oil and install the injector assembly onto the engine.
  6.  
  7. Install and torque the fuel rail mounting bolts to 10 ft. lbs. (14 Nm).
  8.  
  9. Install the fuel pressure regulator onto the fuel rail.
  10.  
  11. Install the fuel supply and return tube and the vacuum crossover hold-down bolt.
  12.  
  13. Connect the fuel injection wiring harness to the engine wiring harness.
  14.  
  15. Connect the vacuum harness to the fuel pressure regulator and fuel rail assembly.
  16.  
  17. Remove the cover from the lower intake manifold and clean the mating surface.
  18.  
  19. Place the intake plenum gasket with the beaded sealant side up, on the intake manifold. Install the air intake plenum and torque the mounting bolts gradually and evenly, in sequence, to 10 ft. lbs. (14 Nm).
  20.  
  21. Connect or install all remaining items that were disconnected or removed during the removal procedure.
  22.  
  23. Refill the cooling system. Connect the negative battery cable and check for leaks using the DRB I or II to activate the fuel pump.
  24.  

 
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