Kia Niro: Intake And Exhaust System / Intake Manifold Repair procedures

Removal and Installation

•	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 Procedure”)

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.

5.	Remove the hybrid starter generator (HSG) connector (A).

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)

7.	Disconnect the positive crankcase ventilation (PCV) hose (A).

8.	Unfasten the electric throttle body control (ETC) module bolts. (Refer to Engine Control / Fuel System - "Electric Throttle Body Control System (ETC)")

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)

10.	Disconnect the hybrid starter generator (HSG) high voltage cable connector (A).

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)

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)

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.

13.

Install in the reverse order of removal.

When installing, replace with new gaskets.

Components 1. Intake manifold gasket 2. Intake manifold 3. Intake manifold stay 4. EGR cooler pipe C gasket 5. Electronic throttle control (ETC) ...

Components 1. Exhaust manifold gasket 2. Exhaust manifold 3. Exhaust manifold stay 4. Heat protector ...

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High Voltage Shut-off Procedures • Be sure to read and follow the “General Safety Information and Caution” before doing any work related with the high voltage system. Failure t ...