This procedure covers removal and replacement of the intake manifold gasket on a 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine, including disconnection of related sensors, fuel rail, and throttle body components.

Warnings

Tools required

Parts

• Intake manifold gasket set × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• Engine coolant × 1 — Hyundai/Kia Long Life Coolant (Green)
• PCV valve grommet (if damaged) × 1 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Park vehicle on level surface and allow engine to cool completely (minimum 2 hours)
2. Disconnect negative battery terminal and wait 3 minutes
3. Remove engine cover by lifting upward on pull tabs
4. Place drain pan under radiator and drain approximately 2 quarts of coolant from petcock or lower radiator hose
5. Relieve fuel system pressure by removing fuel pump fuse and attempting to start engine until it stalls

Procedure

1. 1

   Remove air intake system
   Disconnect the mass airflow sensor electrical connector. Loosen the clamp at the throttle body. Remove the air intake duct and air filter housing assembly by unclipping retaining tabs and removing mounting bolts. Set aside to provide access to the intake manifold area.
2. 2

   Disconnect throttle body electrical connections
   Locate and disconnect the throttle position sensor electrical connector on the throttle body. Press the release tab and pull straight away from the connector. Tag or photograph the connection for reassembly.
3. 3

   Disconnect vacuum lines and hoses
   Disconnect the brake booster vacuum hose from the intake manifold. Disconnect the PCV hose from the valve cover and intake manifold. Disconnect any EVAP purge valve hoses attached to the intake manifold. Label each hose connection location with tape or take detailed photographs.
4. 4

   Remove throttle body
   Remove the four throttle body mounting bolts. Carefully pull the throttle body away from the intake manifold. Inspect the throttle body gasket and replace if damaged. Cover the intake manifold opening with a clean rag to prevent debris entry.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
5. 5

   Disconnect fuel rail and injectors
   Disconnect the fuel supply line from the fuel rail using the appropriate fuel line disconnect tool. Disconnect all fuel injector electrical connectors by pressing the release tabs. Remove the fuel rail mounting bolts and carefully lift the fuel rail with injectors attached straight up and away from the intake manifold. Secure the fuel rail assembly to the side without stressing fuel lines.
   ⚠Have shop rags ready to catch residual fuel. Do not allow fuel to contact hot engine components or electrical connectors.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
6. 6

   Disconnect coolant hoses from intake manifold
   Locate coolant hoses connected to the intake manifold or coolant crossover (if equipped). Use hose clamp pliers to move spring clamps away from connections. Disconnect hoses and allow coolant to drain into pan. If equipped with coolant crossover, remove bolts and separate from intake manifold.
7. 7

   Disconnect remaining sensors and brackets
   Disconnect the manifold absolute pressure (MAP) sensor electrical connector if mounted on intake manifold. Remove any wiring harness brackets or cable brackets bolted to the intake manifold. Disconnect the PCV valve if directly threaded into the manifold. Ensure all electrical connections and hoses are clear of the intake manifold.
8. 8

   Remove EGR valve assembly
   If equipped with an EGR valve, disconnect the EGR valve electrical connector. Remove the EGR valve mounting bolts and carefully separate the EGR valve from the intake manifold. Inspect the EGR gasket and replace if damaged.
9. 9

   Remove intake manifold mounting bolts
   Remove all intake manifold mounting bolts in reverse order from the tightening sequence (working from outside toward center). There are typically 10-12 bolts securing the manifold. Keep bolts organized by location. Once all bolts are removed, carefully lift the intake manifold straight up and away from the cylinder head. If stuck, gently tap with a rubber mallet but do not pry between sealing surfaces.
   ⚠Do not pry between intake manifold and cylinder head as this will damage the sealing surfaces.
10. 10

    Remove old gasket and clean mating surfaces
    Carefully remove the old intake manifold gasket from both the manifold and cylinder head surfaces. Use a plastic gasket scraper to remove all gasket material without scratching the aluminum surfaces. Clean surfaces thoroughly with brake cleaner and wipe with lint-free shop rags. Inspect both mating surfaces for warping or damage. Use compressed air or vacuum to remove any debris from intake ports. Cover intake ports with clean rags during cleaning.
    ⚠Ensure no debris, gasket material, or cleaning solvent enters the intake ports or cylinder head. Foreign material can cause serious engine damage.
11. 11

    Install new gasket and position intake manifold
    Remove protective rags from intake ports. Position the new intake manifold gasket on the cylinder head, ensuring all port openings align correctly and gasket alignment dowels (if present) are properly seated. Carefully lower the intake manifold onto the gasket, aligning all bolt holes. Thread all intake manifold bolts by hand to ensure proper alignment before tightening any bolts.
12. 12

    Torque intake manifold bolts in sequence
    Using a torque wrench, tighten the intake manifold bolts in the proper sequence (center outward) to 25.0 Nm (18.0 lb-ft). Start with the center bolts and work outward in a spiral or crosshatch pattern to ensure even clamping force. Perform torque tightening in two stages: first pass to 12 Nm, second pass to final 25 Nm.
    ⚠Proper torque sequence is critical. Tightening from center outward prevents gasket distortion and ensures even sealing.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
13. 13

    Reinstall EGR valve and coolant components
    If equipped, install the EGR valve with a new gasket and torque bolts to specification. Reconnect the EGR electrical connector. If equipped with coolant crossover, install with new gasket or O-ring and torque bolts to specification. Reconnect coolant hoses and secure with clamps.
14. 14

    Reinstall fuel rail and injectors
    Ensure injector O-rings are in good condition (replace if damaged or dried). Position the fuel rail and injectors into the intake manifold, pressing down firmly to seat all injectors. Install and torque fuel rail bolts to specification. Reconnect all fuel injector electrical connectors. Reconnect the fuel supply line, ensuring it clicks into place securely.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
15. 15

    Reinstall throttle body and complete reassembly
    Install the throttle body with a new gasket and torque bolts to specification. Reconnect the throttle position sensor electrical connector. Reinstall the PCV valve and hose connections. Reconnect all vacuum hoses, EVAP hoses, and brake booster vacuum line to their original locations. Reinstall any wiring harness brackets. Reinstall the air intake system and reconnect the MAF sensor. Reconnect the negative battery terminal.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)

Reassembly

1. Refill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level
2. Verify all electrical connectors are fully seated and locked
3. Double-check that all vacuum hoses and fuel lines are properly connected
4. Reinstall engine cover

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming. Check for fuel leaks around fuel rail connections
• Start engine and allow to reach operating temperature while monitoring for coolant leaks around intake manifold
• Check for vacuum leaks by listening for hissing sounds around intake manifold gasket and throttle body
• Verify smooth idle with no surging or roughness that would indicate vacuum leak
• Test drive vehicle to confirm normal acceleration and no check engine light
• After test drive, recheck coolant level and top off if necessary. Inspect for any fluid leaks around intake manifold area

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