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Home >> Hyundai >> 2018 >> Kona Limited, FWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 1.6L >> Intake Manifold >> Repair Procedures >> Removal And Installation

Removal And Installation

  1. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  2. Disconnect the battery negative terminal.
  3. Disconnect the engine wiring connector and harness clamp and disconnect the wiring from intake manifold.
    G12596300Courtesy of HYUNDAI MOTOR AMERICA
  4. Disconnect the reservoir tank water hose (A).
    G12596301Courtesy of HYUNDAI MOTOR AMERICA
  5. Disconnect the water pipe & pipe mounting bracket (A).
    G12596302Courtesy of HYUNDAI MOTOR AMERICA
  6. Remove the intercooler outlet hose and pipe.
    1. Disconnect the intercooler outlet hose (A).
    2. Disconnect the boost pressure sensor (BPS) connector (B).
    3. Disconnect the RCV solenoid hose (C).
    4. Disconnect the RCV solenoid connector (D).

    Tightening torque: 

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

    G12596303Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
    • The marking of hose must be in line with the stopper of the throttle body.
    • The band must be located on the position mark of hose and must not run over it.
    • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  7. Disconnect the Purge control solenoid valve (PCSV) (A).
    G12596304Courtesy of HYUNDAI MOTOR AMERICA
  8. Remove the ETC module.

    (Refer to Engine Control/Fuel System - "ETC (ELECTRONIC THROTTLE CONTROL) ")

  9. Disconnect the Positive crankcase ventilation (PCV) hose (A).
    G12596305Courtesy of HYUNDAI MOTOR AMERICA
  10. Disconnect the vacuum hose (A).
    G12596306Courtesy of HYUNDAI MOTOR AMERICA
  11. Remove the intake manifold (A) with the gasket.

    Tightening torque: 

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

    G12596307Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • Remove the oil cooler hose mounting bolt (A) when removing.

      Tightening torque: 

      9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 13.7 - 17.4 lb-ft)

      G12596308Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When mounting, check whether the gasket is damaged and replace with a new component if necessary.
    • When installing the intake manifold, tighten the Bolts & nuts with pre-torque first and then tighten the Bolts & nuts with specified torque in the sequence shown in illustration.
      Fig 1: Intake Manifold Bolts Tightening Sequence
      G12596309Courtesy of HYUNDAI MOTOR AMERICA
  12. Install in the reverse order of removal.
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