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Removal And Installation

WARNING: This page is about a different variant/trim than selected.
  1. Remove the engine cover.
  2. Disconnect the battery negative terminal.
  3. Disconnect the engine wiring connector and harness clamp and disconnect the wiring from intake manifold.
    1. Injector extension connector
    2. MAPS (Map Sensor) connector
    3. Knock Sensor connector
    4. Front connector
    5. CKPS (Crank Shaft Position Sensor) connector
    6. vacuum pump extension connector
    7. ETC (Electric Throttle Control) Module connector
    8. PCSV (Purge Control Solenoid Valve) connector
    Fig 1: Engine Wiring Connectors And Harness Clamp
    G12161020Courtesy of KIA MOTORS AMERICA, INC.
  4. Disconnect the PCV (Positive crankcase ventilation) hose (A) and the PCSV (Purge control solenoid valve) hose (B).
    Fig 2: Locating Positive Crankcase Ventilation Hose And Purge Control Solenoid Valve Hose
    G12161021Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the intercooler outlet hose (A).
    Fig 3: Locating Intercooler Outlet Hose
    G12161022Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the vacuum hose (A) and the throttle body coolant hoses (B).
    Fig 4: Locating Vacuum Hose And Throttle Body Coolant Hoses
    G12161023Courtesy of KIA MOTORS AMERICA, INC.
    Fig 5: Locating Throttle Body Coolant Hoses
    G12161024Courtesy of KIA MOTORS AMERICA, INC.
  7. Unfasten the filler neck assembly mounting bolts (A).

    Tightening Torque: 

    6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb.ft)

    Fig 6: Locating Filler Neck Assembly Mounting Bolts
    G12161025Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the vacuum hose (A).
    Fig 7: Locating Vacuum Hose
    G12161026Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the intake manifold (A) with the gasket (B).

    Tightening Torque: 

    18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

    Fig 8: Locating Intake Manifold And Gasket With Bolt
    G12161027Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing, replace with new gaskets.
    When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
    Fig 9: Intake Manifold Bolts And Nuts Tightening Sequence
    G12161028Courtesy of KIA MOTORS AMERICA, INC.
  10. Install in the reverse order of removal.
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