Kia Amanti 2004-06

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Air intake assembly
     

  8.  
  9. Remove the following engine wiring harnesses:
    1. Crankshaft angle sensor
    2.  
    3. Camshaft angle sensor
    4.  
    5. Fuel injector harness
      NOTE
      When disconnecting the injector, lift the fuel supply hose and injector assembly upward. Then unscrew the mounting bolt to lift the fuel supply hose. Reinstall the fuel hose and injector assembly after disconnecting the injector harness.

    6.  
    7. Power steering switch
    8.  
    9. Variable intake motor connector
    10.  
    11. Accelerator position sensor
    12.  
    13. EGR solenoid
    14.  
    15. Throttle position sensor
    16.  
    17. Electronic throttle system (ETS) motor
    18.  
    19. Limp-home connector
    20.  
    21. Purge solenoid valve connector
    22.  

  10.  
  11. Remove or disconnect the following:

    Vacuum hoses and heater hoses between the intake manifold and cylinder head cover
     
    Engine wiring harness bracket
     
    EGR valve hose and bracket
     
    Surge tank assembly
     
    Fuel supply hose
     
    Fuel injector assembly
     
    Timing belt cover
     
    Water pump bracket mounting bolts
     
    Intake manifold mounting nuts
     
    Intake manifold
     

  12.  

To install:

  1. Install the intake manifold with a new gasket and tighten the mounting nuts in sequence to 15-17 ft. lbs. (20-23 Nm).

    Click image to see an enlarged view

    Fig. Intake manifold tightening sequence

  2.  
  3. Install the water pump bracket and tighten the bolts to 15-20 ft. lbs. (20-27 Nm).
  4.  
  5. Install the timing belt covers.
  6.  
  7. Connect the fuel supply hose and install the fuel injector assembly. Tighten to 84-120 inch lbs. (10-13 Nm).
  8.  
  9. Install the surge tank assembly. Tighten to 11-15 ft. lbs. (15-20 Nm).
  10.  
  11. Install the EGR valve hose and tighten the mounting bolts to 12-19 ft. lbs. (17-26 Nm).
  12.  
  13. Install the EGR pipe fixing bracket and tighten the bolts to 11-15 ft. lbs. (15-20 Nm).
  14.  
  15. Install surge tank stay mounting bolts and tighten the bolts to 11-15 ft. lbs. (15-20 Nm).
  16.  
  17. Install the engine wiring harness bracket.
  18.  
  19. Reconnect the vacuum and heater hoses between the intake manifold and cylinder head cover.
  20.  
  21. Reconnect all wiring harnesses that were disconnected during removal.
  22.  
  23. Install the air intake assembly.
  24.  
  25. Install the engine cover.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  

 
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