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Home >> Kia >> 2021 >> Niro Plug-In Hybrid EX >> Repair and Diagnosis >> Engine Mechanical >> Intake And Exhaust System (PHEV) >> Intake Manifold >> Repair Procedures >> Removal And Installation
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

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 Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries.
  1. Shut off the high voltage circuit.

    (Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT-OFF PROCEDURES ")

  2. Remove the air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  3. Remove the engine room under cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  4. Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.
    G13348397Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the hybrid starter generator (HSG) connector (A).
    G13348398Courtesy of KIA MOTORS AMERICA, INC.
  6. 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)

    G13348399Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the positive crankcase ventilation (PCV) hose (A).
    G13348400Courtesy of KIA MOTORS AMERICA, INC.
  8. Unfasten the electric throttle body control (ETC) module bolts.

    (Refer to Engine Control/Fuel System - " REMOVAL  ") 

  9. 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)

    G13348401Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the hybrid starter generator (HSG) high voltage cable connector (A).
    G13348402Courtesy of KIA MOTORS AMERICA, INC.
  11. 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)

    G13348403Courtesy of KIA MOTORS AMERICA, INC.
  12. 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)

    G13348404Courtesy 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 1: Intake Manifold Bolts And Nuts Tightening Sequence
    G13348405Courtesy of KIA MOTORS AMERICA, INC.
  13. Install in the reverse order of removal.
NOTE: When installing, replace with new gaskets.
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