How to Replace the Intake Manifold in a Hyundai Sonata

The Hyundai Sonata offered 1468cc and 1495cc engines in models produced between 1990 and 1993. While these models today have a lot of miles on them, their economy and reliability inspires enthusiasts to rebuild them. The following steps walk you through the removal and installation of the intake manifold.

Instructions

Remove the Intake Manifold

1

Pull the air intake hose form the throttle body and set it aside. Take the accelerator cable from the throttle lever, disconnect the water hose from the water outlet fitting. Then remove the throttle body and the gasket.

2

Disconnect the PCV hose from the rocket cover. Disconnect the brake vacuum hoses and then label and take all the vacuum hoses from their corresponding connections on the intake manifold.

3

Relieve the pressure from the fuel system. Take the fuel hose from the fuel delivery pipe.

4

Remove the bolts from the air intake surge take and pull the tank from the manifold. Locate the fuel injector harness connectors and disconnect them.

5

Loosen the bolts and remove the fuel delivery pipe from the manifold. Handle the injectors carefully. Take out the wiring harness between the water temperature gauge and the water temperature sensor. Label and disconnect the spark plug wires.

6

Remove the distributor and the ignition coil, then take out the manifold stay. Take off the nuts from the intake manifold. Rock it gently back and forth to separate it from the head. Take out the intake manifold gasket.

7

Scrape any gasket material from the manifold and cylinder mating surfaces. Clean the surge tank and all other mating surfaces. Inspect the manifold and surge tank for damage.

Install the Intake Manifold

8

Install a new gasket. Place the intake manifold on the cylinder head studs and then position it to the gasket. Set the nuts in place and finger-tighten them. Torque the nuts to 11 to 14 foot pounds, working out from the center.

9

Bolt the intake manifold stay into place. Torque the retaining bolts to 13 to 18 foot pounds. Install the ignition coil, the distributor and the spark plug wires. Replace the thermostat in the intake manifold.

10

Replace the water outlet fitting with a new gasket. Torque the bolts to 12 to 14 foot pounds. Connect the wiring harness between the temperature sensor and the temperature gauge.

11

Connect the fuel delivery pipe into the intake manifold and torque the bolts to 7 to 9 foot pounds. Torque the bolts to 11 to 14 lbs. Connect the fuel injector harness connectors then put the surge tank and gasket on the manifold.

12

Continue installing and reconnecting hoses, lines and electrical wiring in the reverse order it was removed. Torque the throttle body and new gasket into place with 7 to 9 foot pounds.

13

Reconnect the water hose to the outlet fitting, the accelerator cable to the throttle lever, and then tighten the cable bracket bolts. Connect the air intake hose to the throttle body.

14

Start the engine. Check the ignition timing and adjust it accordingly. Check for fuel, coolant and vacuum leaks.