Hyundai Coupes/Sedans 1994-1998 Repair Guide

Intake Manifold

Imprimir

REMOVAL & INSTALLATION



See Figures 1 through 19



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Fig. Fig. 1: Many electrical harnesses cross the intake manifold. Label each prior to disconnecting



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Fig. Fig. 2: To disconnect the accelerator cable, first loosen the cable bracket adjusting bolts....



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Fig. Fig. 3: ....then remove the cable end from the throttle linkage



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Fig. Fig. 4: The fuel rail is held in place by two bolts which thread into the intake manifold



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Fig. Fig. 5: The fuel injectors and fuel rail are removed as an assembly. Don't forget to disconnect the fuel line



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Fig. Fig. 6: The surge tank is supported by a bracket bolted to the back of the tank....



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Fig. Fig. 7: ....and to the intake manifold. Remove the bolts at the tank and just loosen the bolts at the intake



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Fig. Fig. 8: After removing the surge tank mounting nuts, lift the tank from the intake manifold studs



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Fig. Fig. 9: Using a scraper, remove the old surge tank gasket material from the intake manifold



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Fig. Fig. 10: Remove the intake manifold mounting nuts and bolts....



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Fig. Fig. 11: ....then lift the intake manifold from the cylinder head



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Fig. Fig. 12: Paper towels stuffed in the intake ports keep gasket scrapings from falling into the cylinder head



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Fig. Fig. 13: Surge tank and intake manifold components-1.5L (VIN K) engine



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Fig. Fig. 14: Surge tank and intake manifold components-1.5L (VIN E) engine



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Fig. Fig. 15: Surge tank and intake manifold components-1.5L (VIN E) Turbo engine



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Fig. Fig. 16: Surge tank and intake manifold components-1.5L (VIN J) engine



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Fig. Fig. 17: Surge tank and intake manifold components-1.6L (VIN R) and 1.8L (VIN M) engines



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Fig. Fig. 18: Surge tank and intake manifold components-2.0L (VIN P) engine



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Fig. Fig. 19: Surge tank and intake manifold components-2.0L (VIN F) engine

Except 3.0L (VIN T) Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air intake hose.
  4.  
  5. Disconnect the accelerator cable.
  6.  
  7. Drain the cooling system and disconnect the upper radiator hose.
  8.  
  9. Label and disconnect all wiring harnesses.
  10.  
  11. Remove the throttle body and gasket.
  12.  
  13. Disconnect the PCV hose from the rocker cover and disconnect the brake vacuum hoses.
  14.  
  15. Label and disconnect all vacuum hoses.
  16.  
  17. Relieve the fuel system pressure.
  18.  
  19. Disconnect the high pressure fuel hose connection from the fuel delivery pipe.
  20.  
  21. Remove the surge tank (and gasket) from the intake manifold.
  22.  
  23. Disconnect the fuel injector harness connectors.
  24.  
  25. Remove the fuel delivery pipe with the pressure regulator attached.
  26.  

Take care not to drop the injectors when removing the delivery pipe.

  1. Remove the insulator from the intake manifold and disconnect the heater hose.
  2.  
  3. Disconnect the wiring harness that runs between the water temperature gauge and the water temperature sensor assembly.
  4.  
  5. Remove the water outlet fitting, thermostat and gasket.
  6.  
  7. Label and disconnect the spark plug wires.
  8.  
  9. Remove the distributor and the ignition coil.
  10.  
  11. Remove the intake manifold stay.
  12.  
  13. Remove the intake manifold.
  14.  

To install:
  1. Clean and inspect the intake manifold, cylinder head, surge tank and all other gasket mating surfaces. Inspect the intake manifold and surge tank for cracks. Check the coolant passages for restrictions.
  2.  
  3. Install the intake manifold using a new gasket. Tighten intake manifold nuts to 11-14 ft. lbs. (15-20 Nm). starting from the center and working outwards.
  4.  
  5. Install the intake manifold stay and tighten bolts to 13-18 ft. lbs. (18-25 Nm).
  6.  
  7. Install the ignition coil, distributor, and spark plug wires.
  8.  
  9. Install the thermostat, gasket and water outlet housing. Tighten bolts to 12-14 ft. lbs. (17-20 Nm).
  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. (10-13 Nm).
  14.  
  15. Connect the fuel injector harness connectors.
  16.  
  17. Install the surge tank using a new gasket. Tighten bolts to 11-14 ft. lbs. (15-20 Nm).
  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 using a new gasket. Tighten bolts to 11-16 ft. lbs. (15-22 Nm).
  24.  
  25. Connect all wiring harnesses.
  26.  
  27. Connect the upper radiator hose to the outlet fitting.
  28.  
  29. Install the accelerator cable.
  30.  
  31. Install the air intake hose.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Start the engine and allow it to reach operating temperature.
  36.  
  37. Check for fuel and coolant leaks.
  38.  
  39. Adjust ignition timing, idle speed and accelerator cable.
  40.  

3.0L (VIN T) Engine

See Figure 20



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Fig. Fig. 20: Surge tank and intake manifold components-3.0L (VIN T) engine

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air intake hose.
  4.  
  5. Disconnect the accelerator cable.
  6.  
  7. Drain the cooling system and disconnect the upper radiator hose.
  8.  
  9. Label and disconnect all wiring harnesses.
  10.  
  11. Remove the throttle body and gasket.
  12.  
  13. Disconnect the PCV hose from the rocker cover and disconnect the brake vacuum hoses.
  14.  
  15. Label and disconnect all vacuum hoses.
  16.  
  17. Remove the EGR pipe and gasket.
  18.  
  19. Remove the surge tank (and gasket) from the intake manifold.
  20.  
  21. Relieve the fuel system pressure.
  22.  
  23. Disconnect the high pressure fuel hose and return hose connections.
  24.  
  25. Disconnect the fuel injector harness connectors.
  26.  
  27. Remove the fuel delivery pipe with the pressure regulator attached.
  28.  

Take care not to drop the injectors when removing the delivery pipe.

  1. Remove the water outlet fitting, thermostat and gasket.
  2.  
  3. Remove the intake manifold.
  4.  

To install:
  1. Clean and inspect the intake manifold, cylinder head, surge tank and all other gasket mating surfaces. Inspect the intake manifold and surge tank for cracks. Check the coolant passages for restrictions.
  2.  
  3. Install the intake manifold using a new gasket. Tighten intake manifold nuts to 11-14 ft. lbs. (15-20 Nm). starting from the center and working outwards.
  4.  
  5. Install the thermostat, gasket and water outlet housing. Tighten bolts to 12-14 ft. lbs. (17-20 Nm).
  6.  
  7. Make sure the injector holes are clean. Lubricate the injector O-rings with a drop of clean engine oil.
  8.  
  9. Install the fuel delivery pipe onto the intake manifold. Torque the retaining bolts to 7-9 ft. lbs. (10-13 Nm).
  10.  
  11. Connect the fuel injector harness connectors.
  12.  
  13. Install the surge tank using a new gasket. Ensure the printed surface of the gasket faces upward. Tighten bolts to 11-14 ft. lbs. (15-20 Nm).
  14.  
  15. Connect the intake manifold, brake and PCV vacuum hoses.
  16.  
  17. Install the throttle body using a new gasket. Tighten bolts to 11-16 ft. lbs. (15-22 Nm).
  18.  

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.

  1. Connect all wiring harnesses.
  2.  
  3. Connect the upper radiator hose to the outlet fitting.
  4.  
  5. Install the accelerator cable.
  6.  
  7. Install the air intake hose.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and allow it to reach operating temperature.
  12.  
  13. Check for fuel a