Kia 283103CAA0 Manifold Assembly-Intake

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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.

Proceed by removing the air inlet tube and air filter housing, then disconnect the PCV hose and the brake booster hose.

Reinstall the remaining parts in reverse order, check the coolant level, and run the engine to check for leaks.