Kia Sportage 2005-06

Intake Manifold

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Removal & Installation



2.7L Engines


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Fig. Upper (surge tank) and lower intake manifolds - 2.7L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove air cleaner hose.
  6.  
  7. Disconnect the accelerator cable. 
  8.  
  9. Disconnect the TPS connector (A). 
  10.  
  11. Disconnect the ISA connector (B). 
  12.  
  13. Disconnect the VIS actuator connector (C). 
  14.  
  15. Disconnect the injector connector (D). 
  16.  
  17. Disconnect the PCSV connector (E). 

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    Fig. Connector identification - 2.7L engine

  18.  
  19. Disconnect the PCSV hose. 
  20.  
  21. Disconnect the brake booster vacuum hose. 
  22.  
  23. Disconnect the PCV hose. 
  24.  
  25. Disconnect the IAT sensor connector. 
  26.  
  27. Disconnect the VIS actuator connector. 
  28.  
  29. Disconnect the ground cable from the surge tank assembly. 
  30.  
  31. Remove the surge tank stay. 
  32.  
  33. Remove the surge tank assembly. 
  34.  
  35. Remove the injector assembly.
  36.  
  37. Remove the intake manifold and gasket.
  38.  

To install:

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Fig. Lower intake manifold torque sequence - 2.7L engine

  1. Install the lower intake manifold and gasket. Tighten to 19-21 Nm (14-15 ft. lbs.) 
  2.  
  3. Install the injector assembly.   
  4.  
  5. Install the surge tank assembly.
  6.  
  7. Install the surge tank assembly. Tighten to 15-20 Nm (11-15 ft. lbs.) 
  8.  
  9. Install the surge tank stay. Tighten to 15-20 Nm (11-15 ft. lbs.) 
  10.  
  11. Install the ground cable. 
  12.  
  13. Connect the VIS actuator connector. 
  14.  
  15. Connect the IAT sensor connector. 
  16.  
  17. Connect the PCV hose. 
  18.  
  19. Connect the brake booster vacuum hose. 
  20.  
  21. Connect the PCSV hose. 
  22.  
  23. Connect the PCSV connector. 
  24.  
  25. Connect the injector connector. 
  26.  
  27. Connector the VIS actuator connector. 
  28.  
  29. Connector the ISA connector. 
  30.  
  31. Connector the TPS connector. 
  32.  
  33. Connector the actuator cable. 
  34.  
  35. Install the air cleaner hose.
  36.  
  37. Install the engine cover.
  38.  

2.0L Engine


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Fig. Intake manifold and related parts - 2.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the TPS (Throttle Position Sensor) connector and ISA (Idle Speed Actuator) connector.
  6.  
  7. Disconnect the PCV (Positive Crankcase Ventilation) hose and breather hose.
  8.  
  9. Remove the accelerator cable.
  10.  
  11. Remove the delivery pipe.
  12.  
  13. Remove the heater hose, PCSV (Purge Control Solenoid Valve) and the brake vacuum hose from throttle body and intake manifold.
  14.  
  15. Disconnect the negative cable from the battery.
  16.  
  17. Recover the refrigerant with a recovery/charging station.
  18.  
  19. Loosen the drive belt.

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    Fig. Suction and discharge lines



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    Fig. Compressor mounting



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    Fig. Compressor bolt identification - 2.7L engine. A: 118mm (4.65 in.); B and C: 102mm (4.02 in.); D: 126mm (4.96 in.)

  20.  
  21. Remove the bolts. Then, disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
  22.  
  23. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).
  24.  
  25. Remove the intake manifold stay.
  26.  
  27. Remove the intake manifold.
  28.  
  29. Installation is in the reverse order of removal with new gasket. Observe the following torques:

    Intake manifold: 16-23 Nm (12-16 ft. lbs.)
     
    Intake manifold stay: 18-24 Nm (13-18 ft. lbs.)
     
    Fuel delivery pipe: 18-27 Nm (14-20 ft. lbs.)
     

  30.  

 
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