Kia Sportage: Intake Manifold

Components and Components Location

 Components

1. Intake manifold assembly
2. Electronic throttle body
3. Intake manifold stay
4. Intake manifold gasket

Repair procedures

Removal and Installation

1. Remove the engine cover.

2. Disconnect the battery negative terminal (A).

Tightening torque 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

3. Remove the air cleaner assembly.

1. Remove the air duct (A).
2. Disconnect the breather hose (B), the recirculation hose (C) and brake booster vacuum hose (D).
3. Disconnect the air intake hose (E) and then remove the air cleaner assembly (F).

Tightening torque

Hose clamp bolt: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

Air cleaner assembly bolts: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

4. Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooler inlet pipe & hose assembly (C).

Tightening torque

Hose clamp bolt: 4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

Pipe mounting bolt: 14.7 ~ 19.6 N.m (1.5 ~ 2.0 kgf.m, 10.8 ~ 14.5 lb-ft)

5. Disconnect the boost pressure sensor connector (A) and then remove the intercooler outlet pipe & hose assembly (B).

Tightening torque 4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)

6. Remove the under cover (A).

Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

7. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. (Refer to Cooling system in this group) 8. Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C).

9. Disconnect the А/С compressor switch connector (A), the alternator connector (B), the OPS (Oil pressure switch) connector & injector extension connector (C), the knock sensor connector (D), the MAPS (Manifold absolute pressure sensor) & LAPS (Intake air temperature sensor) connector (E), the ETC (Electronic throttle control) connector (F) and the vacuum pump connector (G).

10. Disconnect the throttle body coolant hoses (A).

11. Remove the oil level gauge (A).

12. Remove the intake manifold stay (A).

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

13. Remove the intake manifold (A) after disconnecting the vacuum hoses.

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

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.

14. Installation is reverse order of removal.

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