Hyundai Kona: Intake and Exhaust System / Intake Manifold Repair procedures

Removal and Installation
1.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
2.
Disconnect the battery negativce terminal.
3.
Disconnect the engine wiring connector and harness clamp and disconnect the wiring from intake manifold.

4.
Disconnect the reservoir tank water hose (A).

5.
Disconnect the water pipe & pipe mounting bracket (A).

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)

  
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).

8.
Remove the ETC module.
(Refer to Engine Control/ Fuel System - "ETC (Electronic Throttle Control")
9.
Disconnect the Positive crankcase ventilation (PCV) hose (A).

10.
Disconnect the vacuum hose (A).

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)

  
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)

  
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.

12.
Install in the reverse order of removal.
Intake Manifold Components and components location
Components 1. Intake manifold assembly 2. Intake manifold gasket 3. Electronic throttle body gasket 4. Electronic throttle body 5. Purge control ...

Exhaust Manifold Components and components location
Components 1. Turbo manifold gasket 2. Turbo manifold module 3. Warm-up catalytic converter (WCC) 4. Warm-up catalytic converter (WCC) gasket 5. Oil feed p ...

Other information:

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