Kia_Sephia_Rio_Spectra_Optima_1998-2006

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure. Disconnect the negative battery cable and drain the cooling system.
  4.  
  5. Remove the air intake hose from the throttle body.
  6.  
  7. Remove the air intake hose and air cleaner assembly, if necessary.
  8.  
  9. Remove the air intake surge tank, if necessary.
  10.  
  11. Disconnect the accelerator cable.
  12.  
  13. Disconnect the fuel lines. Plug the lines to avoid contamination.
  14.  
  15. Disconnect all necessary vacuum hoses and electrical connectors.
  16.  
  17. Remove the coolant hoses.
  18.  
  19. Remove the Exhaust Gas Recirculation (EGR) tube, if equipped.
  20.  
  21. Remove the air valve, if equipped.
  22.  
  23. Remove the fuel rail attaching bolts.
  24.  
  25. Remove the fuel rail and injectors as an assembly.
  26.  
  27. Remove the intake manifold support bracket.
  28.  
  29. Remove the bolt retaining the dipstick tube bracket to the intake manifold, if necessary.
  30.  
  31. Remove the intake manifold-to-cylinder bolts/nuts and the intake manifold assembly.
  32.  
  33. Remove the throttle body, if necessary and separate the intake manifold upper and lower halves.

    Click image to see an enlarged view

    Fig. Exploded view of intake manifold assembly-1.6L (VIN 3)



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold assembly-1.8L engine shown



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2.4L engine



    Click image to see an enlarged view

    Fig. Exploded view of the intake manifold-2.7L engine

  34.  

To install:

Click image to see an enlarged view

Fig. Intake manifold torque sequence-1.8L engine

  1. Clean all gasket mating surfaces.
  2.  
  3. Install the upper and lower intake manifolds using a new gasket, if separated. Tighten the nuts/bolts to 19 ft. lbs. (25 Nm).
  4.  
  5. Install the throttle body using a new gasket, if removed. Tighten the retaining nuts/bolts to 19 ft. lbs. (25 Nm).
  6.  
  7. Install the intake manifold assembly to the cylinder head using a new gasket. Tighten the nuts/bolts to 11-14 ft. lbs. (15-20 Nm) for 1.5L, 1.6L and 2.7L engines, or 13-16.5 ft. lbs. (18-22.5 Nm) for 2.0L engine, or to 19 ft. lbs. (25 Nm) for 1.8L and 2.4L engines.
    NOTE
    Tighten the bolts in the center of the manifold first and work outward toward the ends.

  8.  
  9. Install the bolt retaining the dipstick tube to the intake manifold, if equipped.
  10.  
  11. Install the intake manifold bracket. Tighten the attaching nuts/bolts to 19 ft. lbs. (25 Nm).
  12.  
  13. Install the EGR tube, if equipped.
  14.  
  15. Connect the coolant and vacuum hoses, electrical connectors and fuel lines.
  16.  
  17. Connect the accelerator cable.
  18.  
  19. Install the air intake surge tank, if removed.
  20.  
  21. Install the air cleaner assembly, if removed.
  22.  
  23. Install the air intake tube to the throttle body.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Fill the cooling system.
  28.  
  29. Start the engine and bring to normal operating temperature. Check for leaks. Check the idle speed.
  30.  

 
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