This procedure covers the removal and installation of the intake manifold on a 2016-2024 Hyundai Tucson with the 2.5L I4 gasoline engine, including disconnection of fuel lines, throttle body, and associated sensors.

Warnings

Tools required

Parts

• Intake manifold gasket × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve (if damaged) × 1 — Use OEM specification
• Vacuum hose clamps (as needed) × 4 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 1.5 qt

Preparation

1. Ensure engine is completely cold to the touch
2. Disconnect the negative battery cable and wait 3 minutes for airbag system capacitors to discharge
3. Remove the engine cover by pulling upward on the cover to release retaining clips
4. Relieve fuel system pressure: Remove fuel pump fuse, start engine and let it run until it stalls, then crank for 5 seconds
5. Partially drain cooling system by opening radiator drain plug until level is below intake manifold connections (approximately 2 quarts)
6. Take photos of all vacuum line routing and electrical connector positions for reference during reassembly
7. Label all vacuum lines with tape and marker indicating connection points

Procedure

1. 1

   Disconnect throttle body and air intake system
   Loosen the air intake hose clamp at the throttle body. Disconnect the mass airflow sensor electrical connector. Remove the air intake duct assembly from the throttle body. Disconnect the throttle position sensor and any additional throttle body electrical connectors. Remove the four throttle body mounting bolts and carefully separate the throttle body from the intake manifold. Set aside with gasket.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect fuel rail and injector connections
   Disconnect all fuel injector electrical connectors by pressing the release tab and pulling straight up. Using the appropriate fuel line disconnect tool, disconnect the high-pressure fuel supply line from the fuel rail. Have shop towels ready to catch any residual fuel. Cap the fuel line to prevent contamination. Remove the fuel rail mounting bolts.
   ⚠️Fuel may spray even after pressure relief. Wear safety glasses and keep towels ready.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
3. 3

   Remove fuel rail assembly
   Carefully pull the fuel rail straight up to disengage injectors from the intake manifold. Keep the assembly level to avoid bending injectors. Place the fuel rail and injector assembly on a clean surface away from the work area. Do not allow injectors to hang by electrical connectors.
   ⚠Fuel injectors can be damaged if rail is pulled at an angle. Lift straight up with even pressure.
4. 4

   Disconnect PCV system and vacuum lines
   Disconnect the PCV valve from the intake manifold by rotating counterclockwise and pulling out. Disconnect the PCV hose from the valve cover connection. Disconnect all vacuum lines from the intake manifold, including brake booster line, purge valve line, and any other vacuum-operated accessories. Refer to photos taken during preparation.
   Torque spec

   PCV Valve8 Nm (6 lb-ft)
5. 5

   Disconnect coolant and remaining sensors
   Disconnect coolant hoses connected to the intake manifold or throttle body (if equipped with coolant passages). Have drain pan positioned to catch coolant. Disconnect any remaining sensors including manifold absolute pressure (MAP) sensor if equipped. Remove any wiring harness brackets or clips attached to the intake manifold.
   ⚠Coolant will drain from hoses. Be prepared with drain pan to prevent spills.
6. 6

   Remove intake manifold support brackets
   Locate and remove any support brackets connecting the intake manifold to the engine block or cylinder head. These may include one or more brackets secured with mounting bolts. Keep track of bracket positions and hardware for reinstallation.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
7. 7

   Remove intake manifold bolts and manifold
   Remove all intake manifold mounting bolts in reverse order from the tightening sequence (working from outside bolts toward center). Once all bolts are removed, carefully lift the intake manifold straight up from the cylinder head. If manifold is stuck, gently tap with a rubber mallet at designated boss points. Do not pry between sealing surfaces.
   ⚠Do not pry between manifold and head sealing surfaces as this will cause damage requiring machining.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
8. 8

   Clean mating surfaces
   Remove the old intake manifold gasket completely. Using a plastic scraper or soft wire brush, carefully clean all gasket material from both the intake manifold and cylinder head mating surfaces. Ensure no debris falls into the intake ports. Wipe surfaces clean with shop towels. Inspect for any damage, warping, or cracks on both surfaces.
   ⚠Cover intake ports with clean shop towels to prevent debris from entering the engine.
9. 9

   Install new gasket and position intake manifold
   Position the new intake manifold gasket on the cylinder head, ensuring all port openings align correctly and gasket locating pins engage properly. Carefully lower the intake manifold onto the gasket, aligning all bolt holes. Ensure the manifold seats evenly on the gasket without shifting the gasket position.
   ℹ️Do not use gasket sealant unless specifically required by service manual. Most modern gaskets are designed to seal without additional sealant.
10. 10

    Install and torque intake manifold bolts
    Install all intake manifold bolts hand-tight. Using a torque wrench, tighten the bolts to specification in the proper sequence starting from the center bolts and working outward in a crisscross pattern. Make two passes: first to 50% torque (12-13 Nm), then final pass to full specification. Verify the tightening sequence with the factory service manual.
    ⚠Improper tightening sequence or torque can cause vacuum leaks or manifold warping. Follow center-out pattern strictly.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
11. 11

    Reinstall support brackets and sensors
    Reinstall intake manifold support brackets and torque mounting bolts to specification. Reconnect all sensors including MAP sensor if equipped. Reinstall wiring harness brackets and clips to the intake manifold. Ensure all electrical connections are secure and connector locks are engaged.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)
12. 12

    Reconnect PCV system and vacuum lines
    Install the PCV valve into the intake manifold, tightening to specification. Reconnect the PCV hose to the valve cover. Reconnect all vacuum lines to their original positions using labels and photos for reference. Ensure all connections are fully seated and clamps are secure.
    Torque spec

    PCV Valve8 Nm (6 lb-ft)
13. 13

    Install fuel rail assembly
    Lubricate fuel injector O-rings with a small amount of clean engine oil. Carefully position the fuel rail and injector assembly over the intake manifold. Press down evenly on the fuel rail until all injectors are fully seated in their bores. Install fuel rail mounting bolts and torque to specification following the sequence outlined in the service manual.
    ⚠Ensure injectors seat straight into bores. Cocked injectors will leak or be damaged.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)
14. 14

    Reconnect fuel line and injector connectors
    Reconnect the high-pressure fuel supply line to the fuel rail, ensuring the connection clicks into place securely. Tug gently to verify connection. Reconnect all fuel injector electrical connectors, ensuring each clicks and locks into position. Verify each connector is fully seated.
    ℹ️Fuel line connection must click audibly. An incomplete connection will cause fuel leaks under high pressure.
15. 15

    Reinstall throttle body and air intake
    Install a new throttle body gasket on the intake manifold. Position the throttle body onto the manifold and install mounting bolts. Torque throttle body bolts to specification using proper sequence as outlined in service manual. Reconnect all throttle body electrical connectors. Reinstall the air intake duct assembly and tighten the clamp. Reconnect the mass airflow sensor connector.
    Torque spec

    Throttle Body Bolts10 Nm (7 lb-ft)

Reassembly

1. Reconnect all coolant hoses that were disconnected and secure with clamps
2. Refill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level
3. Reinstall the fuel pump fuse that was removed during pressure relief
4. Reconnect the negative battery cable
5. Reinstall the engine cover by aligning clips and pressing down until seated

Verification

• Turn ignition to ON position (without starting) and listen for fuel pump priming. Inspect all fuel connections for leaks
• Start the engine and allow it to idle. Check for fuel leaks at fuel rail and supply line connections
• Inspect for vacuum leaks by listening for hissing sounds and checking idle stability. Idle should be smooth without fluctuation
• Check for coolant leaks at all reconnected hose connections
• Verify throttle response is smooth and immediate with no hesitation
• Allow engine to reach operating temperature and verify no check engine light illuminates
• Scan for diagnostic trouble codes using OBD-II scanner to confirm no fault codes are present
• Test drive vehicle to verify normal operation under load and acceleration

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