SORENTO ICV Replacement (SC073)

Publication date: 2008-05-01
Reference number: SC073

SORENTO ICV REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 073, Date of Issue: May 2008

KIA:	2003-05 Sorento with 3.5L Sigma Engine
GROUP:	Campaign

Description

SORENTO ICV REPLACEMENT

This Service Campaign provides information related to replacing the Induction Control Valve Sub Assembly (ICV). Some 2003~2005 MY Sorento's equipped with a 3.5L engine may exhibit engine noise or rattle type noise if the anti-rattle clip / throttle screws or two piece bushing become loose and get ingested into the engine assembly. Vehicles that were previously repaired with the improved version part will be excluded from this service campaign.

To correct this condition, Kia has outlined a service procedure to replace the induction control valve (ICV) with an improved version to prevent possible future engine damage. Changes and improvements were made on the throttle plate shaft bushing and sealing O-rings. Use ONLY the following part number (29222 39800QQK) to service the vehicle under this service campaign.

Fig 1: Identifying Surge Tank, Valve Sub Assembly And Intake Manifold Assembly

Courtesy of KIA MOTORS AMERICA, INC.

Inspection Procedure

Open hood and check for SC073 Campaign completion label on the panel above the under hood fuse box. If label exists, NO FURTHER ACTION IS REQUIRED.

If label does not exist, continue to step 1.

Fig 2: View Of Label

Courtesy of KIA MOTORS AMERICA, INC.

Record the radio presets, open the hood and disconnect the negative battery cable.

Fig 3: Identifying Negative Battery Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the engine cover as shown and remove the air intake hose to the throttle body.

Fig 4: Identifying Air Intake Hose To Throttle Body
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the electrical connectors from the intake manifold assembly and throttle body and reposition to allow manifold removal.
1. Partially drain cooling system.
  
  Fig 5: Disconnecting Electrical Connectors From Intake Manifold Assembly And Throttle Body
  Courtesy of KIA MOTORS AMERICA, INC.
Remove and re-position the steel coolant transfer line.

Fig 6: Identifying Steel Coolant Transfer Line
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the accelerator and cruise control cables from the throttle body and intake manifold.
1. Disconnect coolant hoses at the bottom of the throttle body.
  
  Fig 7: Disconnecting Accelerator And Cruise Control Cables
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the front and rear intake manifold assembly retaining nuts and washers.
1. Install the nuts and tighten together as shown in photo.
  
  Fig 8: Identifying Nuts
  Courtesy of KIA MOTORS AMERICA, INC.
Use the jam-nuts to remove the front and rear stud from the Surge Tank assembly to the lower intake manifold.

Fig 9: Removing Front And Rear Stud
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the retaining bolts on the stay brackets and remove the upper bolts from the bracket only. Removing the RH stay brackets is not necessary.

Fig 10: Identifying Upper Bolts And Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove bolt for L/F corner stay bracket to Surge Tank and loosen the lower retaining bolts.

Fig 11: Identifying Bolt For L/F Corner Stay Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove bolt for L/R stay bracket and wiring harness retainer.
1. Disconnect the negative ground cable from the manifold assembly.
  
  Fig 12: Identifying Bolt For L/R Stay Bracket
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the front stay bracket from the intake manifold assembly.

Fig 13: Identifying Front Stay Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the brake booster vacuum hose clamp and disconnect the rubber hose from the steel line mounted on the bulkhead.

Fig 14: Disconnecting Rubber Hose
Courtesy of KIA MOTORS AMERICA, INC.
1. Disconnect the fuel pressure regulator vacuum supply hose located next to brake booster hose on Intake Manifold Assembly.
Remove the surge tank assembly from the vehicle.

Fig 15: Removing Surge Tank Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Using a clean work surface, remove the Intake Control Valve (ICV) from the Surge Tank.

Fig 16: Identifying Surge Tank
Courtesy of KIA MOTORS AMERICA, INC.
Clean the mating surfaces and install new sealing gaskets between the ICV and Surge Tank. These gaskets are included in the service kit.

Fig 17: Identifying New Sealing Gaskets
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Follow torque procedure as outlined during assembly.

Fig 18: Idemtifying Bolt Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Install ICV to the Surge Tank. Install the seven (7) Allen Head screws and torque to 84 inch lbs. (9.4 Nm).

Fig 19: Installing ICV To Surge Tank
Courtesy of KIA MOTORS AMERICA, INC.
Transfer the vacuum valve to the new lower intake manifold, tighten the screws to 84 inch lbs. (9.4 Nm).
1. Use new supplied C-clip and screws when transferring vacuum control Valve.
  
  Fig 20: View Of Vacuum Valve
  Courtesy of KIA MOTORS AMERICA, INC.
Clean the mating surfaces and install new Intake Manifold to Surge Tank Assembly gasket. Carefully install the Surge Tank Assembly.
NOTE: Take care not to pinch wire harness or vacuum hose between the ICV and lower Intake Manifold.

Fig 21: Installing Intake Manifold To Surge Tank Assembly Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Install the front mounting stud first as shown, make sure gasket is in proper position. Hand tighten the stud two (2) complete revolutions, leave loose until all bolts are installed on both the manifold and stay brackets.

Fig 22: Identifying Front Mounting Stud
Courtesy of KIA MOTORS AMERICA, INC.
1. Lift the rear of the manifold until the gasket and bolt aligns in the proper position.
2. Using a flashlight, inspect the marked area for proper gasket alignment before proceeding.
3. Continue to install remainder of Surge Tank to Lower Intake Manifold bolts and stud.
Torque Specifications:
- Depression Chamber Body (Vacuum Valve) 84 inch lbs. (9.4 Nm).
- Surge Tank to Induction Control Valve - 84 in. lbs. (9.4 Nm).
- Complete Upper Intake Manifold to Lower Intake Manifold Bolt and Nuts - 11~14 ft lbs. (14.9 ~ 18.9 Nm).
- All stay brackets from Intake Manifold Assembly to other related engine components - 15 ~ 20 ft. lbs. (20.3 ~ 27.1 Nm).
  
  Fig 23: Identifying Surge Tank To Intake Manifold Torque Sequence
  Courtesy of KIA MOTORS AMERICA, INC.
Install the remainder of the components in the reverse order of removal.
Re-fill and bleed the cooling system using removed coolant.
Connect the negative battery cable and set the customers preset radio stations and clock time.
1. If equipped with overhead console, convert to US measurements by pressing the Up/Down button for 1 second.
2. If equipped with Automatic Climate Control, convert to US measurements by depressing the temperature down button and AMB button for 3 seconds.
  
  Fig 24: View Of Cooling System
  Courtesy of KIA MOTORS AMERICA, INC.
Road test to verify proper operation as normal service procedure.
Install the SC073 completion label on the panel above the under hood fuse box.

Fig 25: View Of SC073 Completion Label On Panel
Courtesy of KIA MOTORS AMERICA, INC.

AFFECTED VEHICLE RANGE

Vehicle Production Range from 6/19/2002 ~ 4/21/2005 (unless previously repaired)

PARTS INFORMATION

Part Name	New Part No.	Quantity
Valve Sub-Assembly Induction	29222 39800QQK	1
SC073 Campaign Completion Label	UK030 SC073	1

Part Number 29222 39800 QQK includes the following:

Intake Control Valve (ICV)
Vacuum Valve C-clip
Vacuum Valve screws
Surge Tank Gasket
Gasket S - ICV
Gasket P - ICV

WARRANTY CLAIM INFORMATION

Claim Type

Causal P/N

Qty.

N Code

C Code

Repair Description

Labor Op Code

Time

Replacement Parts

Qty.

29221 39800

N29

C04

Replace Intake Control Valve (ICV)

080003R0

1.5⁽¹⁾

29222 39800QQK

⁽¹⁾	Includes drain/refill coolant, clear codes, install ICV.

Use sublet code of S7 for reimbursement of $2.25 per vehicle; this will provide a coolant allowance for 1 pint of concentrate Kia Engine Coolant mixed at 50/50. This will equal 1 qt. total of engine coolant. Only fill with new coolant if necessary.