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Home >> Hyundai >> 2020 >> Sonata SEL >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 10 (Intake And Exhaust System - 1.6L (Except HEV)) >> Intake Manifold >> Repair Procedures >> Removal And Installation

Removal And Installation

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  1. Disconnect the battery negative terminal.

    Tightening torque: 

    3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

    G14524531Courtesy of HYUNDAI MOTOR AMERICA
  2. Remove the engine cover.
    G14524532Courtesy of HYUNDAI MOTOR AMERICA
  3. Remove the air duct (A).
    G14524533Courtesy of HYUNDAI MOTOR AMERICA
  4. Remove the air cleaner assembly.
    1. Disconnect the RCV hose (A).
    2. Disconnect the breather hose (B).
    3. Disconnect the intake air hose (C).
    4. Disconnect the air flow sensor (AFS) connector (D).
    5. Remove the air cleaner assembly (E).

      Tightening torque: 

      Hose Clamp: 2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)

      Air Cleaner Assembly: 3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 Ib-ft)

      G14524534Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • Align the marks (A) of the air intake hose.
        G14524535Courtesy of HYUNDAI MOTOR AMERICA
  5. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
    G14524536Courtesy of HYUNDAI MOTOR AMERICA
  6. Remove the intercooler outlet hose (A).
    G14524537Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    1. When disconnect the intercooler inlet hose, pull out the quick connector clamp (A) in the direction of the arrow as shown in the illustration below.
      G14524538Courtesy of HYUNDAI MOTOR AMERICA
    2. Move the quick connector clamp from position (B) to position (C) as shown in the illustration below and pull out the quick connector hose.
      G14524539Courtesy of HYUNDAI MOTOR AMERICA
      G14524540Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the Purge control solenoid valve (PCSV) hose (A).
    G14524541Courtesy of HYUNDAI MOTOR AMERICA
  8. Remove the water return hose & pipe bracket bolt (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    G14524542Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the Intake Manifold (A).

    Tightening torque: 

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

    G14524543Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing, replace with new gaskets.

      When installing the intake manifold, tighten sequence shown.

      Fig 1: Intake Manifold Bolts Tightening Sequence
      G14524544Courtesy of HYUNDAI MOTOR AMERICA
  10. Install in the reverse order of removal.