Santa Fe, Vera Cruz 2006-2008

Intake Manifold

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Removal & Installation



2.7L Engine

Specific to:

Hyundai Santa Fe 2006-2008

  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
     
    Engine Coolant Temperature (ECT) sensor 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)
     
    ECT 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.  

3.3L & 3.8L Engines

Specific to:

Hyundai Santa Fe 2007-2008

Hyundai Veracruz 2007-2008

  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.  

3.5L Engine

Specific to:

Hyundai Santa Fe 2006

  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 Engine Coolant Temperature (ECT) sensor 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.
  12.  
  13. Install the surge tank stay and tighten the retainers to: 11-14 ft. lbs. (15-20 Nm).
  14.  
  15. Attach the vacuum hose connectors.
  16.  
  17. Connect the PCV valve and brake booster vacuum hoses.
  18.  
  19. Connect the engine coolant hose to the throttle body.
  20.  
  21. Connect the air breather hose to the throttle body.
  22.  
  23. Connect the negative battery cable.
  24.  
  25. Start the engine and check for proper operation.
  26.  

 
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