Kia Sportage 1998-02

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. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cable bracket bolts from the valve cover
     
    Air intake tube to cylinder head cover bolts
     
    Air intake tube to throttle body bolts
     
    Loosen the clamp attaching the air tube to the Mass Air Flow (MAF) sensor
     
    Idle Air Control (IAC) valve, breather hose and vacuum line from the air intake tube
     
    Air intake tube
     
    Positive Crankcase Ventilation hose (PCV) from the dynamic chamber
     
    Purge solenoid valve vacuum hose from the dynamic chamber
     
    Throttle Position (TP) sensor electrical connector
     
    IAC valve electrical connector
     
    Heater hoses
     
    Engine-to-body ground strap from the intake manifold and the harness bracket below it
     
    Brake booster vacuum line
     
    Vacuum hose from the fuel pressure regulator hose
     
    Dynamic chamber support bracket bolts
     
    Fuel injector electrical connectors
     
    Fuel pressure and return lines
     
    Intake manifold support bracket
     
    Oil filter
     
    Intake manifold bolts
     
    Bypass pipe from the heater hose
     
    Intake manifold and discard the gasket
     

  8.  

To install:



Click image to see an enlarged view

Fig. Intake manifold mounting bolt locations. Be sure to connect the ground cable

  1. Install or connect the following:

    Intake manifold with a new gasket to the cylinder head
     
    Heater hose to the bypass pipe
     
    Bolts and nuts attaching the intake manifold to the cylinder head. Torque the bolts to 14-22 ft. lbs. (19-30 Nm).
     
    New oil filter
     
    Intake manifold support bracket. Torque the bolts to 27-38 ft. lbs. (37-52 Nm)
     
    Fuel lines
     
    Fuel injector electrical connectors
     
    Engine to body ground wire. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Dynamic chamber support bracket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Purge solenoid valve vacuum hose to the dynamic chamber
     
    Vacuum hose to the fuel pressure regulator
     
    Coolant hoses to the throttle body
     
    IAC valve electrical connector
     
    Brake booster vacuum hose
     
    Heater hoses
     
    TP sensor electrical connector
     
    Air intake tube and hose to the throttle body. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    PCV hose to the dynamic chamber
     
    Accelerator cable to the throttle body pulley
     
    Accelerator cable bracket. Torque the bolts to 10 ft. lbs. (15 Nm).
     
    Air intake hose to the MAF sensor
     
    Resonance chamber
     
    IAC hose, breather hose and vacuum line to the intake manifold
     
    Negative battery cable
     

  2.  
  3. Properly fill the cooling system.
  4.  
  5. Start the engine and check for leaks, repair if necessary.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the intake, exhaust manifold and related components


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section .
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cable bracket bolts from the valve cover
     
    Air intake tube to cylinder head cover bolts
     
    Air intake tube to throttle body bolts
     
    Loosen the clamp attaching the air tube to the Mass Air Flow (MAF) sensor
     
    Idle Air Control (IAC) valve, breather hose and vacuum line from the air intake tube
     
    Air intake tube
     
    Positive Crankcase Ventilation hose (PCV) from the dynamic chamber
     
    Purge solenoid valve vacuum hose from the dynamic chamber
     
    Throttle Position (TP) sensor electrical connector
     
    IAC valve electrical connector
     
    Heater hoses
     
    Engine-to-body ground strap from the intake manifold and the harness bracket below it
     
    Brake booster vacuum line
     
    Vacuum hose from the fuel pressure regulator hose
     
    Dynamic chamber support bracket bolts
     
    Fuel injector electrical connectors
     
    Fuel pressure and return lines
     
    Intake manifold support bracket
     
    Oil filter
     
    Intake manifold bolts
     
    Bypass pipe from the heater hose
     
    Intake manifold and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold mounting bolt locations. Be sure to connect the ground cable

  1. Install or connect the following:

    Intake manifold with a new gasket to the cylinder head
     
    Heater hose to the bypass pipe
     
    Bolts and nuts attaching the intake manifold to the cylinder head. Torque the bolts to 14-22 ft. lbs. (19-30 Nm).
     
    New oil filter
     
    Intake manifold support bracket. Torque the bolts to 27-38 ft. lbs. (37-52 Nm)
     
    Fuel lines
     
    Fuel injector electrical connectors
     
    Engine to body ground wire. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    Dynamic chamber support bracket. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Purge solenoid valve vacuum hose to the dynamic chamber
     
    Vacuum hose to the fuel pressure regulator
     
    Coolant hoses to the throttle body
     
    IAC valve electrical connector
     
    Brake booster vacuum hose
     
    Heater hoses
     
    TP sensor electrical connector
     
    Air intake tube and hose to the throttle body. Torque the bolts to 16 ft. lbs. (22 Nm).
     
    PCV hose to the dynamic chamber
     
    Accelerator cable to the throttle body pulley
     
    Accelerator cable bracket. Torque the bolts to 10 ft. lbs. (15 Nm).
     
    Air intake hose to the MAF sensor
     
    Resonance chamber
     
    IAC hose, breather hose and vacuum line to the intake manifold
     
    Negative battery cable
     

  2.  
  3. Properly fill the cooling system.
  4.  
  5. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the intake, exhaust manifold and related components

  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Accelerator cable bracket bolts from the valve cover
     
    Air intake tube to cylinder head cover bolts
     
    Air intake tube to throttle body bolts
     
    Loosen the clamp attaching the air tube to the Mass Air Flow (MAF) sensor
     
    Idle Air Control (IAC) valve, breather hose and vacuum line from the air intake tube
     
    Air intake tube
     
    Positive Crankcase Ventilation hose (PCV) from the dynamic chamber
     
    Purge solenoid valve vacuum hose from the dynamic chamber
     
    Throttle Position (TP) sensor electrical connector
     
    IAC valve electrical connector
     
    Heater hoses
     
    Engine-to-body ground strap from the intake manifold and the harness bracket below it
     
    Brake booster vacuum line
     
    Vacuum hose from the fuel pressure regulator hose
     
    Dynamic chamber support bracket bolts
     
    Fuel injector electrical connectors
     
    Fuel pressure and return lines
     
    Intake manifold support bracket
     
    Oil filter
     
    Intake manifold bolts
     
    Bypass pipe from the heater hose
     
    Intake manifold and discard the gasket
     

  8.  

To install:

Click image to see an enlarged view

Fig. Intake manifold mounting bolt locations. Be sure to connect the ground cable

  1. Install or connect the following:

    Intake manifold with a new gasket to the cylinder head
     
    Heater hose to the bypass pipe
     
    Bolts and nuts attaching the intake manifold to the cylinder head. Torque the bolts to 14-22 ft. lbs. (19-30 Nm)
     
    New oil filter
     
    Intake manifold support bracket. Torque the bolts to 27-38 ft. lbs. (37-52 Nm)
     
    Fuel lines
     
    Fuel injector electrical connectors
     
    Engine to body ground wire. Torque the bolt to 18 ft. lbs. (25 Nm)
     
    Dynamic chamber support bracket. Torque the bolts to 18 ft. lbs. (25 Nm)
     
    Purge solenoid valve vacuum hose to the dynamic chamber
     
    Vacuum hose to the fuel pressure regulator
     
    Coolant hoses to the throttle body
     
    IAC valve electrical connector
     
    Brake booster vacuum hose
     
    Heater hoses
     
    TP sensor electrical connector
     
    Air intake tube and hose to the throttle body. Torque the bolts to 16 ft. lbs. (22 Nm)
     
    PCV hose to the dynamic chamber
     
    Accelerator cable to the throttle body pulley
     
    Accelerator cable bracket. Torque the bolts to 10 ft. lbs. (15 Nm)
     
    Air intake hose to the MAF sensor
     
    Resonance chamber
     
    IAC hose, breather hose and vacuum line to the intake manifold
     
    Negative battery cable
     

  2.  
  3. Properly fill the cooling system.
  4.  
  5. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Exploded view of the intake, exhaust manifold and related components

  6.  

 
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