Hyundai Sonata: Intake Manifold. Repair procedures - Intake And Exhaust System - Engine Mechanical SystemHyundai Sonata: Intake Manifold. Repair procedures

Removal and Installation

1.
Remove the engine cover.
2.
Disconnect the battery negative terminal (A).
Tightening torque
4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
3.
Remove the air duct (B).
4.
Remove the air cleaner assembly.
(1)
Disconnect the breather hose (A), the intensifier hose (B) and brake booster vacuum hose (C).
(2)
Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).
Tightening torque
Hose clamp bolt:
2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
Air cleaner assembly bolts:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

5.
Remove the under cover.
6.
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
(Refer to Cooling system in this group)
7.
Disconnect the intake OCV (Oil control valve) connector (A).
8.
Disconnect the VIS (Variable intake system) connector (A), the OPS (Oil pressure switch) connector (B), the injector extension connector (C), the knock sensor connector (D), the alternator connector (E) and the air compressor connector (F).
9.
Disconnect the ETC (Electronic throttle control) connector (A) and MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B).
10.
Disconnect the PCV (Positive crankcase ventilation) hose (A).
11.
Disconnect the vacuum hose (A) and PCSV (Purge control solenoid valve) hose (B).
12.
Disconnect the throttle body coolant hoses (A).
13.
Remove the oil level gauge (A).
14.
Remove the intake manifold stay (A).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

15.
Remove the intake manifold (A) with the gasket (B).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

When installing, replace with new gaskets.
When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
16.
Installation is reverse order of removal.

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