Hyundai 28310-25081 Manifold Assembly-Intake

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Intake manifolds are best removed by first releasing the fuel system pressure and then disconnecting the cable from the battery's negative terminal. Next, remove the engine cover and the air intake duct assembly off the car to get to the throttle body. Remove the PCV hose, ground strap, electrical connectors and vacuum connectors from the upper intake manifold, noting which clip attaches to which. Pry the wiring harnesses up; for any hose and harness that is in the vicinity, ensure that it is labeled and disconnected. Remove the access cover protecting the throttle body and bend the hoses to remove the coolant from the work area. Seven, loosen and remove the upper manifold brace(s) bolts, remove the bolts from the EGR valve and if any more brackets are in place, remove them and organise them properly. Break the nuts holding the upper intake manifold with the lower one and disengage the two pieces. The procedures for the lower intake manifold are removal of the cooling system, the removal of electrical connectors from the fuel injectors, removal of fuel line from fuel rail. Depending on the need, the intake manifold can be removed together with the injectors and the fuel rails in place or individually. Remove any fittings from the remaining components if still connected to the lower manifold; the mounting bolts, then take off the lower intake manifold from the engine, but do not pry the gasket surfaces apart. Look at the manifold in your car and see if its surface is deformed. For installation use scraper for removing of old gasket material and sealant for cleaning the mating surfaces and for putting of new gaskets then for placing of lower intake manifold on the engine. E xplain that when replacing gaskets the inside one should be aligned properly and the bolts inserted and fully tightened in a certain order. Put a new gasket at the lower and upper intake manifolds, place the upper manifold and fasten the bolts starting from certain numbers. Last, replace the cooling system with the fresh one in case the lower intake manifold has been removed; change the engine oil and the filter and start the engine and look for the leaks.

On 2010 and earlier models, remove the fuel rail along with the injectors (see Chapter 4).