Kia 283103CAA0 Intake Manifold Assembly

The intake manifolds can be removed by beginning with the relief of the fuel system pressure in the event one is working on 2005 or earlier model or when removing the lower manifold on any model; the negative battery cable should be disconnected. Pop off the engine cover and for the models that precede the year 2005, cut off the accelerator and the cruise control cables. Subsequently, unfasten the air inlet tube at the air filter housing with about six hose clamps, also turn off the PCV hose and brake booster hose, clamp the ground strap, detach the electrical connectors and vacuum pipes that are found at the upper intake manifold and the air intake, and it is recommended that you tag the connectors for reassembly. On the models from 2005 and before, you would have to remove the fuel supply line in the pressure regulator, the nuts for the upper intake manifold support, and then you had to remove the hoses and the electrical connectors associated with the throttle body; remember to block the coolant hoses in order to prevent any spills. Remove the lower electrical connectors of different sensors and actuators then, unbolt the upper intake manifold. Dispense the liquid cool-ant, take off the thermostat housing, and the thermostat on the 2005 and earlier models, unplug the electrical connectors of the fuel injectors, and unbolt the fuel terminal on the fuel rail, besides moving the wire harness to one side. In the 2006 and later models, the intake manifold may be removed with the injectors and the fuel rails thus being in or out depending on the extent of work to be performed. Removing any remaining screws disconnect the components from the lower manifold, while the final bolts used are removed in reverse sequence turn them loose and remove the lower intake manifold from the engine; do not pry between the gasket mating surfaces to avoid damaging it. Inspect the manifold for signs of wear and tear or ramp of which violation would mean the need for a new manifold. In the case of installation, first, razor off the old gasket and sealant on the lower intake manifold and cylinder heads, clean the surfaces and then fit the gaskets and place the lower intake manifold on the engine such that gaskets do not come off in the process of tightening the bolts and tighten them as per the required sequence. New gasket should be put between the lower and upper intake manifolds, the upper one placed on the lower one, and the bolts should be tightened evenly up to the given torque. Lastly, add more coolant, start the engine and checking for any fuel, vacuum or coolant leakage.

To begin the removal process, relieve the fuel system pressure and disconnect the cable from the negative terminal of the battery. Next, remove the engine cover. For 2006 and earlier models, disconnect the accelerator and cruise control cables. Proceed by removing the air inlet tube and air filter housing, then disconnect the PCV hose and the brake booster hose. Disconnect the ground strap, electrical connectors, and vacuum lines from the upper intake manifold, labeling each connector for correct reassembly, and pull the wiring harnesses aside. For 2006 and earlier models, clamp off the coolant lines to the throttle body and disconnect them; for 2007 and later models, drain the engine coolant and disconnect the heater hoses from the heater core tubes at the firewall. Remove the upper intake manifold support brackets and disconnect the electrical connectors and hoses to the throttle body, taking care to clamp off the coolant hoses before detaching them to prevent spillage. Disconnect the electrical connectors to the various sensors and move the harness out of the way, then remove the bolts mounting the upper intake manifold to the lower intake manifold. Drain the cooling system and disconnect the electrical connectors from the fuel injectors, also detaching the fuel line from the fuel rail while pulling the wiring harness aside. The intake manifold can be removed with the injectors and fuel rails in place or separately, depending on the work required. Disconnect any remaining components from the lower manifold, then remove the mounting bolts in reverse order of tightening, detaching the lower intake manifold from the engine without prying between the gasket mating surfaces to avoid damage. Check the manifold's surface with a precision straightedge and replace it if excessively deformed. For installation, use a scraper to remove old gasket material and sealant from the lower intake manifold and cylinder heads, cleaning the mating surfaces with brake system cleaner. Install new gaskets and position the lower intake manifold on the engine, ensuring the gaskets haven't shifted before installing and tightening the bolts in three or four equal steps to the specified torque. Install a new gasket between the lower and upper intake manifolds, place the upper intake manifold on the lower intake manifold, and tighten the bolts gradually to the specified torque. Finally, refill the cooling system, run the engine, and check for fuel, vacuum, and coolant leaks.