Hyundai Santa Fe 2001-05

Intake Manifold

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Removal & Installation



2.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air breather hose from the throttle body
     
    Throttle and cruise control cables
     
    Engine coolant hose and throttle body
     
    Positive Crankcase Ventilation (PCV) valve and brake booster vacuum hose
     
    Vacuum hose connector
     
    Surge tank stay
     
    High pressure fuel hose
     
    Surge tank and gasket
     
    Fuel injector harness connector
     
    Delivery pipe with the injectors and the pressure regulator as an assembly
     
    Coolant Temperature Sensor (CTS) electrical connector
     
    Intake manifold
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2.7L engine


To install:



Click image to see an enlarged view

Fig. Intake manifold torque sequence-2.7L engine

  1. Install or connect the following:

    New intake manifold gasket
     
    Intake manifold and tighten the bolts to 14-15 ft. lbs. (19-21 Nm)
     
    CTS electrical connector
     
    Delivery pipe with the injectors and the pressure regulator as an assembly
     
    Fuel injector harness connector
     
    Surge tank and gasket
     
    High pressure fuel hose
     
    Surge tank stay
     
    Vacuum hose connector
     
    PCV valve and brake booster vacuum hose
     
    Engine coolant hose and throttle body
     
    Throttle and cruise control cables
     
    Air breather hose from the throttle body
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper operation.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air breather hose from the throttle body
     
    Throttle and cruise control cables
     
    Engine coolant hose and throttle body
     
    Positive Crankcase Ventilation (PCV) valve and brake booster vacuum hose
     
    Vacuum hose connector
     
    Surge tank stay
     
    High pressure fuel hose
     
    Surge tank and gasket
     
    Fuel injector harness connector
     
    Delivery pipe with the injectors and the pressure regulator as an assembly
     
    Coolant Temperature Sensor (CTS) electrical connector
     
    Intake manifold

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2.7L engine

     

  4.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-2.7L engine

  1. Install or connect the following:

    New intake manifold gasket
     
    Intake manifold and tighten the bolts to 14-15 ft. lbs. (19-21 Nm)
     
    CTS electrical connector
     
    Delivery pipe with the injectors and the pressure regulator as an assembly
     
    Fuel injector harness connector
     
    Surge tank and gasket
     
    High pressure fuel hose
     
    Surge tank stay
     
    Vacuum hose connector
     
    PCV valve and brake booster vacuum hose
     
    Engine coolant hose and throttle body
     
    Throttle and cruise control cables
     
    Air breather hose from the throttle body
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for proper operation.
  4.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air breather hose from the throttle body.
  6.  
  7. Remove the Positive Crankcase Ventilation (PCV) valve and brake booster vacuum hoses.
  8.  
  9. Disconnect the vacuum hose connections.
  10.  
  11. Remove the surge tank stay.
  12.  
  13. Remove the surge tank and gasket.
  14.  
  15. Disconnect the fuel injector harness connector.
  16.  
  17. Remove the delivery pipe with the injectors and the pressure regulator as an assembly.
  18.  
  19. Disconnect the Coolant Temperature Sensor (CTS) electrical connector.
  20.  
  21. Remove the intake manifold bolts, manifold and gasket.
  22.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-3.5L engine


To install:



Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.5L engine

  1. Install a new intake manifold gasket.
  2.  
  3. Install the intake manifold and tighten the bolts in the sequence illustrated to 14-16 ft. lbs. (20-23 Nm)
  4.  
  5. Attach the CTS electrical connector.
  6.  
  7. Install the delivery pipe with the injectors and the pressure regulator as an assembly.
  8.  
  9. Attach the fuel injector harness connector.
  10.  
  11. Install the surge tank and gasket.

    Surge tank stay and tighten the retainers to 11-14 ft. lbs. (15-20 Nm).
     

  12.  
  13. Attach the vacuum hose connectors.
  14.  
  15. Connect the PCV valve and brake booster vacuum hoses.
  16.  
  17. Connect the engine coolant hose to the throttle body.
  18.  
  19. Connect the air breather hose to the throttle body.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for proper operation.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air breather hose from the throttle body.
  6.  
  7. Remove the Positive Crankcase Ventilation (PCV) valve and brake booster vacuum hoses.
  8.  
  9. Disconnect the vacuum hose connections.
  10.  
  11. Remove the surge tank stay.
  12.  
  13. Remove the surge tank and gasket.
  14.  
  15. Disconnect the fuel injector harness connector.
  16.  
  17. Remove the delivery pipe with the injectors and the pressure regulator as an assembly.
  18.  
  19. Disconnect the Coolant Temperature Sensor (CTS) electrical connector.
  20.  
  21. Remove the intake manifold bolts, manifold and gasket.

    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-3.5L engine

  22.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-3.5L engine

  1. Install a new intake manifold gasket.
  2.  
  3. Install the intake manifold and tighten the bolts in the sequence illustrated to 14-16 ft. lbs. (20-23 Nm)
  4.  
  5. Attach the CTS electrical connector.
  6.  
  7. Install the delivery pipe with the injectors and the pressure regulator as an assembly.
  8.  
  9. Attach the fuel injector harness connector.
  10.  
  11. Install the surge tank and gasket.

    Surge tank stay and tighten the retainers to 11-14 ft. lbs. (15-20 Nm).
     

  12.  
  13. Attach the vacuum hose connectors.
  14.  
  15. Connect the PCV valve and brake booster vacuum hoses.
  16.  
  17. Connect the engine coolant hose to the throttle body.
  18.  
  19. Connect the air breather hose to the throttle body.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Start the engine and check for proper operation.
  24.  

 
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