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Repair Procedures

Disconnect the battery negative terminal from the battery.
Remove the air duct(A).

Fig 1: Identifying Air Duct
Courtesy of HYUNDAI MOTOR CO.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A).
2. Disconnect the ECM connectors (B).
3. Disconnect the AFS connector (C) and then remove the air cleaner assembly (D).
  Tightening torque
  
  7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
4. Step 4 consist of illustration only
  
  Fig 2: Locating Air Cleaner Upper Cover And Intake Hose
  Courtesy of HYUNDAI MOTOR CO.
Remove the under cover (A).
Tightening torque

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

Fig 3: Identifying Under Cover
Courtesy of HYUNDAI MOTOR CO.
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the engine wiring connectors, the harness protectors and mounting clamps.
1. RH front, rear oxygen sensor connectors (A).
2. Power steering oil pressure sensor connector (B).
3. VIS solenoid valve connector (C).
4. RH exhaust camshaft OCV connector (D).
5. RH injector connector (E).
6. Condenser connector (A).
7. RH ignition coil connector (B).
8. Knock sensor connector (C).
9. LH/RH intake camshaft OCV connector (D).
10. LH exhaust camshaft OCV connector (E).
11. LH injector connectors (F).
12. LH ignition coil connectors (A).
13. LH exhaust CMPS connector (B).
14. LH front oxygen sensor connector (A).
15. Alternator connector (A) and the 'B' terminal cable (B).
16. LH intake CMPS connector (A) and the oil pressure switch connector (B).
17. PCSV connector (A).
18. MAP sensor connector (B).
19. RH intake CMPS connector (C).
20. ETC connector (D).
21. OTS connector (E).
22. Knock sensor connector (B) and the RH exhaust CMPS connector (A).
23. WTS & gauge unit connector (A).
24. LH rear oxygen sensor connector (A) and the CKPS connector (B).
Disconnect the throttle body coolant hoses (A), the brake booster vacuum hose (B) and the fuel hose (C).
Tightening torque :

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

Fig 14: Identifying Throttle Body Coolant Hoses (A), The Brake Booster Vacuum Hose (B) And The Fuel Hose (C)
Courtesy of HYUNDAI MOTOR CO.
Remove the throttle body (A).
Tightening torque :

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

Fig 15: Identifying Trottle Body
Courtesy of HYUNDAI MOTOR CO.
Remove the surge tank stay (A).
Tightening torque:

27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)

Fig 16: Identifying Surge Tank Bracket
Courtesy of HYUNDAI MOTOR CO.
Remove surge tank stay (A).
Tightening torque:

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

Fig 17: Identifying Surge Tank
Courtesy of HYUNDAI MOTOR CO.
Disconnect the LH injector connectors.
Remove the delivery pipe & injector assembly (A).

Fig 18: Identifying Delivery Pipe & Injector Assembly (A)
Courtesy of HYUNDAI MOTOR CO.
Remove the intake the manifold (A).

Fig 19: Identifying The Intake Manifold (A)
Courtesy of HYUNDAI MOTOR CO.
CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.
Installation is reverse order of removal.

Tighten the intake manifold bolts and nuts, in several passes as below.

Tightening torque:

Step 1: 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Step 2:Nut- 18.6 ~ 23.5N.m (1.9~2.4kgf.m, 13.7~17.4lb-ft)

Bolt -26.5 ~ 31.4N.m (2.7~3.2kgf.m, 19.5~23.1lb-ft)

Step 3: Repeat 2nd step twice or more.

a ~ h : 1st step order

1 ~ 8 : 2nd step order

NOTE: Confirm the manifold gasket identification mark (LH, RH) and be careful of the installation direction.

Fig 20: Locating Intake Manifold And Gasket Tightening Sequence

G00510040

Courtesy of HYUNDAI MOTOR CO.