Removal And Installation

Disconnect the battery negative terminal (A).
Tightening torque:

4.0 ~ 6.0 N.m (0.4 ~ 0.6 kgf.m, 3.0 ~ 4.4 lb-ft)
Remove the engine cover (B).

Fig 1: Battery Negative Terminal & Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A) and the BARO (Barometric pressure) sensor connector (B).
2. Disconnect the air intake hose and then remove the air cleaner assembly (C).
Tightening torque

Hose clamp bolt:

2.9 ~ 4.9 N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6 lb-ft)

Air cleaner assembly bolts:

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

Fig 2: Breather Hose, BARO Sensor Connector & Air Cleaner Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the under cover.
Loosen the drain plug (A), and drain the coolant. Remove the radiator cap to speed draining.
CAUTION: Never remove the radiator cap when the engine is hot.
Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.

Fig 3: Radiator Drain Plug
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the wiring connectors, harness clamps and hoses from the engine.
1. Power steering pump oil pressure switch.
2. RH front, rear oxygen sensor connector (A) and loosen the power steering hose mounting bolts (B).
  
  Fig 4: Oxygen Sensor Connectors & Power Steering Hose Mounting Bolts
  Courtesy of KIA MOTORS AMERICA, INC.
3. VIS connector (A).
4. RH exhaust camshaft OCV connector (B).
5. RH ignition coil connector (C).
6. RH injector connector (D).
  
  Fig 5: VIS, OCV & Ignition Coil Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. LH exhaust camshaft OCV connector (A).
8. LH/RH intake camshaft OCV connector (B).
9. Oil pressure switch connector (C).
10. Knock sensor connector (D).
11. Condenser connector (E).
12. Ground (F).
13. LH front oxygen sensor connector (G).
  
  Fig 6: Camshaft OCV, Oil Pressure Switch, Knock Sensor & Condenser Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
14. Alternator connector (A).
  
  Fig 7: Alternator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
15. LH ignition coil connectors (A).
16. LH injector connectors (B).
17. LH intake CMPS connector (C).
  
  Fig 8: Ignition Coil, Injector & CMPS Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
18. MAP sensor connector (A).
19. PCSV connector (B).
  
  Fig 9: MAP Sensor & PCSV Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
20. RH intake CMPS connector (A)
21. ETC connector (B)
22. OTS connector (C)
23. Knock sensor connector (D)
24. RH exhaust CMPS connector (E)
  
  Fig 10: CMPS, ETC, OTS & Knock Sensor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the PCSV hose (A), fuel hose (B), brake booster vacuum hose (C), PCV hose (D).

Fig 11: PCSV Hose, Fuel Hose, Brake Booster Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the throttle body coolant hoses (A).
Remove the throttle body mounting bolt (B).
Tightening torque:

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

Fig 12: Throttle Body Coolant Hoses & Throttle Body Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Remove the surge tank stay (A).
Tightening torque:

27.5 ~ 31.4 N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1 lb-ft)

Fig 13: Surge Tank Stay
Courtesy of KIA MOTORS AMERICA, INC.
Remove the surge tank (A).
Tightening torque:

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

Fig 14: Surge Tank
Courtesy of KIA MOTORS AMERICA, INC.
Remove the delivery pipe & injector assembly (A).

Fig 15: Delivery Pipe & Injector Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake the manifold (A).

Fig 16: Intake Manifold
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Cover the inlet of cylinder head with a clean cloth or vinyl cover to prevent foreign materials from entering the engine.
Installation is reverse order of removal.
Tighten the intake manifold bolts and nuts, in several passes as below.

Tightening torque

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

Step 2: Nut- 18.62 ~ 23.52 N.m (1.9~2.4 kgf.m, 13.74~17.36 lb-ft)

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

Step 3: Repeat 2nd step twice or more.

a - h : 1st step order

1 ~ 8 : 2nd step order

Fig 17: Intake Manifold Bolt Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.