Kia Sorento 2003-05

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the air intake hose connected to the throttle body.
  10.  
  11. Remove the accelerator and cruise control cables.
  12.  
  13. Remove the engine coolant hose and throttle body.
  14.  
  15. Remove the PCV hose and brake booster vacuum hoses.
  16.  
  17. Disconnect the vacuum hose connections.
  18.  
  19. Remove the surge tank stay.
  20.  
  21. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.
  22.  
  23. Disconnect the connector from high pressure hose.
  24.  
  25. Remove the surge tank and gasket.
  26.  
  27. Disconnect the fuel injector harness connector.
  28.  
  29. Remove the delivery pipe with the fuel injector and the pressure regulator.
  30.  
  31. Disconnect the wiring harness of the coolant sensor assembly.
  32.  
  33. Remove the intake manifold.
  34.  


    Click image to see an enlarged view

    Fig. Intake manifold torque sequence


To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Lower intake manifold nuts, in sequence to: 15-17 ft. lbs. (20-23 Nm)
     
    Surge tank stay bolts: 11-14 ft. lbs. (15-20 Nm)
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the air intake hose connected to the throttle body.
  10.  
  11. Remove the accelerator and cruise control cables.
  12.  
  13. Remove the engine coolant hose and throttle body.
  14.  
  15. Remove the PCV hose and brake booster vacuum hoses.
  16.  
  17. Disconnect the vacuum hose connections.
  18.  
  19. Remove the surge tank stay.
  20.  
  21. Bleed off the pressure in the fuel pipe line to prevent the fuel from spilling.
  22.  
  23. Disconnect the connector from high pressure hose.
  24.  
  25. Remove the surge tank and gasket.
  26.  
  27. Disconnect the fuel injector harness connector.
  28.  
  29. Remove the delivery pipe with the fuel injector and the pressure regulator.
  30.  
  31. Disconnect the wiring harness of the coolant sensor assembly.
  32.  
  33. Remove the intake manifold.

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence



    Click image to see an enlarged view

    Fig. Intake manifold and related components

  34.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Lower intake manifold nuts, in sequence to: 15-17 ft. lbs. (20-23 Nm)
     
    Surge tank stay bolts: 11-14 ft. lbs. (15-20 Nm)
     

  2.  

 
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