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Home >> Kia >> 2021 >> K5 GT-Line, AWD >> Repair and Diagnosis >> Engine Mechanical >> Intake And Exhaust System - 1.6L >> Intake Manifold >> Repair Procedures >> Removal And Installation
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Removal And Installation

  1. Disconnect the battery negative terminal.
  2. Remove the engine cover.

    (Refer to " Removal And Installation  ") 

  3. Remove the air duct.

    (Refer to " Removal and Installation  ") 

  4. Remove the engine room under cover.

    (Refer to " Removal And Installation  ") 

  5. Disconnect the engine wiring connector and harness clamp and disconnect the wiring from intake manifold.

    Tightening torque: 

    7.8 - 9.8 N.m (0.8 -1.0 kgf.m, 5.8 - 7.2 lb.ft)

    G13833514Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the intercooler outlet pipe (A).
    G13833515Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    1. To remove the intercooler tube, pull out the quick connector clip (A) in the direction of the arrow shown in the image below
      G13833516Courtesy of KIA MOTORS AMERICA, INC.
    2. As shown in the figure below, move the quick connector clamp B to C, and then pill out the quick connector tube.
      G13833517Courtesy of KIA MOTORS AMERICA, INC.
    G13833518Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the purge control solenoid valve (PCSV) hose (A).
    G13833519Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the water return hose and pipe bracket mounting bolts (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 -1.2 kgf.m, 7.2 - 8.7 lb.ft)

    G13833520Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the purge control solenoid valve (PCSV) (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 -1.2 kgf.m, 7.2 - 8.7 lb.ft)

    G13833521Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the Electronic Throttle Control (ETC) module.

    (Refer to "Removal "

  11. Remove the intake manifold (A) with the gasket.

    Tightening torque: 

    18.6 - 23.5 N.m (1.9-2.4 kgf.m, 13.7-17.3 lb.ft)

    G13833522Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Do not reuse the intake manifold gasket.
  12. Install in the reverse order of removal.
    NOTE: When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
Fig 1: Intake Manifold Bolts And Nuts Tightening Sequence
G13833523Courtesy of KIA MOTORS AMERICA, INC.
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