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Home >> Kia >> 2009 >> Sorento Base, A5SR2 >> Repair and Diagnosis >> Engine Mechanical >> Intake And Exhaust System >> Intake Manifold >> Repair Procedures >> Replacement
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Repair Procedures: Replacement

  1. Drain the engine coolant. (Refer to "RADIATOR ".)
    CAUTION: Drain the engine coolant before removing intake manifold, or coolant flow into intake port from vent hole of cylinder head.
    In that case you may have some problem in combustion chamber.
  2. Remove the engine cover.
    Fig 1: Identifying Engine Cover
    G06407852Courtesy of KIA MOTORS AMERICA, INC.
  3. Remove the engine room resonator (A).
    Fig 2: Identifying Engine Room Resonator
    G06407853Courtesy of KIA MOTORS AMERICA, INC.
  4. After disconnecting the MAF sensor connector (A) and the breather hose (B), remove the air cleaner assembly (C).
    Fig 3: Identifying MAF Sensor Connector, Breather Hose And Air Cleaner Assembly
    G06407854Courtesy of KIA MOTORS AMERICA, INC.
  5. Disconnect the other breather hose (A), the Purge Control Solenoid Valve (PCSV) hose, the Positive Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses (D) and connector (E).
    Fig 4: Identifying Crankcase Ventilation (PCV) Hose, Electronic Throttle Control (ETC) Cooling Hoses And Connector
    G06407855Courtesy of KIA MOTORS AMERICA, INC.
    Fig 5: Identifying Other Breather Hose
    G06407856Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the wiring over the surge tank.
    1. Disconnect the injection harness connector (A).
    2. Disconnect the camshaft position sensor (CMP) harness connector (B).
    3. Disconnect the ground line (C).
    4. Disconnect the ignition coil harness connector (D).
    5. Disconnect the condenser connector (E).
    6. Disconnect the variable induction system (VIS) solenoid valve connector (G).
    7. Disconnect the oil control valve (OCV) harness connector (F).
    8. Disconnect the injector wiring (H) and ignition coil wiring (I).
      Fig 6: Identifying Injection Harness Connector, CMP Harness Connector, Ignition Coil Harness Connector And Condenser Connector
      G06407857Courtesy of KIA MOTORS AMERICA, INC.
      Fig 7: Identifying Variable Induction System (VIS) Solenoid Valve Connector, Injector Wiring And Ignition Coil Wiring
      G06407858Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the fuel hose tube (A).
    Fig 8: Identifying Fuel Hose Tube
    G06407859Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove heater hose (A) and disconnect the brake vacuum hose (B).
    Fig 9: Identifying Heater Hose And Brake Vacuum Hose
    G06407860Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the surge tank stay.
  10. Remove the surge tank.
  11. Disconnect the injector connectors.
  12. Disconnect the water hose on intake manifold from the nipple on the chain cover.
  13. Remove the delivery pipe and intake manifold as an assembly.
    NOTE: Except such cases as defects of injectors or pipe, do not disassemble a delivery pipe from an intake manifold because it is one of the fuel system parts, or you may have some problem in fuel system.
  14. Install intake manifold and new gasket on the cylinder head.

    Tightening torque 

    1st: 3.9 ~ 5.9 Nm (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

    2nd

    Bolt: 26.5 ~ 31.4 Nm (2.7 ~ 3.2 kgf.m, 19.5 ~ 23.1 lb-ft)

    Nut: 18.6 ~ 23.5 Nm (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

    3rd: Repeat 2nd step twice or move.

    NOTE: Be careful of the installation direction.
    a - h: 1st step order
    1 ~ 8: 2nd step order
    Fig 10: Intake Manifold Bolts Tightening Sequence
    G06407861Courtesy of KIA MOTORS AMERICA, INC.
  15. Connect the water hose on intake manifold to the nipple on the chain cover.
  16. Install delivery pipe.
  17. Install the surge tank and new gasket on the intake manifold.

    Tightening torque 

    Long bolt: 9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

    Short bolt, nut: 18.6 ~ 23.5 Nm (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

  18. Connect heater hose (A) and the brake vacuum hose (B).
    Fig 11: Identifying Heater Hose And Brake Vacuum Hose
    G06407862Courtesy of KIA MOTORS AMERICA, INC.
  19. Connect the fuel hose tube (A).
    Fig 12: Identifying Fuel Hose Tube
    G06407863Courtesy of KIA MOTORS AMERICA, INC.
  20. Connect the wiring over the surge tank.
    1. Connect the injection harness connector (A)
    2. Connect the camshaft position sensor (CMP) harness connector (B).
    3. Connect the ground lines (C).
    4. Connect the ignition coil harness connector (D).
    5. Connect the condenser connector (E).
    6. Connect the variable induction system (VIS) solenoid valve connector (G).
    7. Connect the oil control valve (OCV) harness connector (F).
      Fig 13: Identifying Ignition Coil Harness Connector, Condenser Connector, VIS Solenoid Valve Connector And OCV Harness Connector
      G06407864Courtesy of KIA MOTORS AMERICA, INC.
  21. Connect the other breather hose (A), the Positive Crankcase Ventilation (PCV) hose (C) and the Electronic Throttle Control (ETC) cooling hoses (D), ETC connector (E).
    Fig 14: Identifying PCV Hose And Electronic Throttle Control (ETC) Cooling Hoses And Connector
    G06407865Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Identifying Breather Hose
    G06407866Courtesy of KIA MOTORS AMERICA, INC.
  22. After connecting the MAF sensor connector (A) and the breather hose (B), install the air cleaner assembly (C).
    Fig 16: Identifying MAF Sensor Connector, Breather Hose And Air Cleaner Assembly
    G06407867Courtesy of KIA MOTORS AMERICA, INC.
  23. Install the engine room resonator (A).
    Fig 17: Identifying Engine Room Resonator
    G06407868Courtesy of KIA MOTORS AMERICA, INC.

    Tightening torque 

    9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

  24. Remove the engine cover (A).
    Fig 18: Identifying Engine Cover
    G06407869Courtesy of KIA MOTORS AMERICA, INC.

    Tightening torque 

    9.80 ~ 11.76 Nm (1.0 ~ 1.2 kgf.m, 7.23 ~ 8.68 lb-ft)

  25. Fill with engine coolant. (Refer to "RADIATOR " in this group)
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