Removal And Installation

WARNING:

Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage circuit according to the "HIGH VOLTAGE SHUT-OFF PROCEDURE " before doing any work related with the high voltage system to avoid serious electrical injuries.

Shut-Off the high voltage circuit.
(Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.

Fig 1: Disconnecting Wiring Connectors And Harness Clamps
Courtesy of KIA MOTORS AMERICA, INC.
Remove the Hybrid Starter Generator (HSG) connector (A).

Fig 2: Removing Hybrid Starter Generator (HSG) Connector
Courtesy of KIA MOTORS AMERICA, INC.
Separate the Hybrid Starter Generator (HSG) coolant hose & pipe (A).
Tightening Torque :

8.8 - 10.9 N.m (0.9 - 1.1 kgf.m, 6.5 - 8.0 lb.ft)

Fig 3: Separating Hybrid Starter Generator (HSG) Coolant Hose & Pipe
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the Positive Crankcase Ventilation (PCV) hose (A).

Fig 4: Disconnecting Positive Crankcase Ventilation (PCV) Hose
Courtesy of KIA MOTORS AMERICA, INC.
Unfasten the Electric Throttle Body Control (ETC) Module Bolts.
(Refer to Engine Control/Fuel System - "ETC (ELECTRONIC THROTTLE CONTROL) SYSTEM ")
Unfasten the EGR cooler pipe C mounting nuts (A).
Tightening Torque :

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb.ft)

Fig 5: Removing EGR Cooler Pipe C Mounting Nuts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the hybrid starter generator (HSG) high voltage cable connector (A).

Fig 6: Disconnecting Hybrid Starter Generator (HSG) High Voltage Cable Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake manifold stay (A).
Tightening Torque :

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

Fig 7: Removing Intake Manifold Stay
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake manifold (A) with the gasket.
Tightening Torque :

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

Fig 8: Removing Intake Manifold With Gasket
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the intake manifold, tighten the bolts and nuts, and then tighten the bolts and nuts to the specified torque in the sequence shown.

Fig 9: Intake Manifold Bolts And Nuts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.
NOTE: When installing, replace with new gaskets.