Removal and Installation

WARNING: This page is about a different variant/trim than selected.

Disconnect the battery negative terminal.
Remove the air duct.
(Refer to Intake And Exhaust System - "AIR CLEANER ")
Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooler inlet pipe & hose assembly (C).
Tightening torque

Hose clamp bolt:

4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

Pipe mounting bolt:

14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

Fig 1: Locating Recirculation Valve Connector, Vacuum Hose And Intercooler Inlet Pipe Or Hose Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the boost pressure sensor connector (A) and then remove the intercooler outlet pipe & hose assembly (B). Tightening torque:
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

Fig 2: Locating Boost Pressure Sensor Connector And Intercooler Outlet Pipe Or Hose Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover ")
Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.
(Refer to Cooling system - "COOLANT ")
Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C).

Fig 3: Locating PCV Hose, Intake Oil Control Valve Connector And Oil Temperature Sensor Connector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the wiring connectors and harness clamps and remove the connector brackets around the intake manifold.

Fig 4: Wiring Connectors And Harness Clamps
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the throttle body coolant hoses (A).

Fig 5: Locating Throttle Body Coolant Hoses
Courtesy of HYUNDAI MOTOR AMERICA
Remove the oil level gauge (A).

Fig 6: Locating Oil Level Gauge
Courtesy of HYUNDAI MOTOR AMERICA
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)

Fig 7: Locating Intake Manifold Stay
Courtesy of HYUNDAI MOTOR AMERICA
Remove the intake manifold (A) after disconnecting the vacuum hoses.
Tightening torque:

18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

Fig 8: Locating Intake Manifold
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: 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

Fig 9: Intake Manifold Bolts And Nuts Tightening Sequence
Courtesy of HYUNDAI MOTOR AMERICA
Install in the reverse order of removal.