Intake Manifold Gasket

This procedure covers removal and replacement of the intake manifold gasket on the 2015 Kia Forte 1.8L I4 engine, including disconnection of fuel, coolant, vacuum lines, and electrical connections.

Warnings

Tools required

Parts

• Intake manifold gasket × 1 — Use OEM specification
• Throttle body gasket × 1 — Use OEM specification
• PCV valve grommet × 1 — Replace if damaged
• Coolant crossover O-rings × 1 — Replace if equipped

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 2 qt

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery cable and wait 3 minutes for system discharge
3. Remove engine cover by pulling upward on all four corners
4. Place drain pan under radiator and drain coolant until level is below intake manifold
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
6. Label all vacuum lines, electrical connectors, and hoses with tape for reassembly reference

Procedure

1. 1

   Disconnect air intake system
   Loosen clamp at throttle body and disconnect air intake tube. Remove air filter housing if needed for access. Disconnect breather hose from valve cover.
2. 2

   Remove throttle body
   Disconnect throttle body electrical connector. Remove four throttle body mounting bolts and carefully remove throttle body from intake manifold. Set aside with gasket.
   Torque spec

   Throttle Body Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect fuel system
   Disconnect fuel line from fuel rail using appropriate fuel line disconnect tool. Have rags ready to catch residual fuel. Disconnect fuel injector electrical connectors and remove fuel rail mounting bolts. Carefully lift fuel rail with injectors attached and secure out of the way.
   ⚠Some fuel will spill when disconnecting lines. Have rags ready and avoid ignition sources.
   Torque spec

   Fuel Rail Bolts12 Nm (9 lb-ft)
4. 4

   Disconnect EGR and PCV systems
   If equipped with EGR valve, disconnect electrical connector and coolant hoses, then remove EGR valve mounting bolts. Disconnect PCV valve from valve cover by twisting counterclockwise and pulling out. Remove PCV hose from intake manifold.
5. 5

   Disconnect vacuum lines and sensors
   Disconnect brake booster vacuum line from intake manifold. Disconnect MAP sensor electrical connector. Remove vacuum lines to EVAP purge valve and any other vacuum connections to intake manifold. Disconnect intake manifold runner control solenoid if equipped.
6. 6

   Disconnect coolant crossover
   If equipped with coolant crossover pipe at rear of intake manifold, disconnect coolant hoses and remove crossover mounting bolts. Remove coolant crossover and O-rings.
7. 7

   Remove intake manifold support bracket
   Locate and remove any support brackets connecting intake manifold to engine block or cylinder head. These are typically at the rear of the manifold.
8. 8

   Remove intake manifold
   Remove intake manifold mounting bolts in reverse order from tightening sequence (outside to center). Carefully lift intake manifold away from cylinder head. If manifold is stuck, gently tap with rubber mallet - do not pry between sealing surfaces.
   ⚠Do not pry between manifold and head surfaces as this will damage sealing surfaces.
   Torque spec

   Intake Manifold Bolts25 Nm (18 lb-ft)
9. 9

   Remove old gasket and clean surfaces
   Remove old intake manifold gasket from cylinder head. Using plastic gasket scraper, carefully clean all gasket material from both intake manifold and cylinder head mating surfaces. Wipe surfaces clean with brake cleaner and lint-free cloth. Inspect for damage, warping, or cracks. All surfaces must be completely clean and dry.
   ⚠Use only plastic scrapers on aluminum surfaces. Metal tools will gouge the soft aluminum and cause leaks.
10. 10

    Install new gasket and position intake manifold
    Place new intake manifold gasket on cylinder head, ensuring all ports align correctly. Carefully position intake manifold onto gasket, ensuring gasket does not shift during installation. Start all intake manifold bolts by hand to ensure proper thread engagement.
11. 11

    Torque intake manifold bolts
    Tighten intake manifold bolts to 25 Nm (18 lb-ft) in sequence from center outward. Use a crisscross pattern starting with center bolts and working toward outer bolts. Verify all bolts are torqued to specification.
    ℹ️Proper torque sequence is critical to prevent gasket leaks and manifold warping. Always start from center and work outward.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)
12. 12

    Install support bracket and coolant crossover
    Reinstall intake manifold support bracket and torque mounting bolts to specification. If equipped, install new O-rings on coolant crossover pipe, install crossover, and torque bolts to specification. Reconnect coolant hoses.
13. 13

    Reconnect vacuum lines and sensors
    Reconnect all vacuum lines to intake manifold using labels as reference. Connect MAP sensor electrical connector, brake booster vacuum line, EVAP purge valve connection, and any other vacuum connections. Ensure all connections are secure.
14. 14

    Install EGR and PCV systems
    Install PCV valve into valve cover with new grommet if needed, torque to specification, and connect hose to intake manifold. If equipped with EGR valve, install with new gasket and torque bolts to specification. Reconnect electrical connector and coolant hoses.
15. 15

    Install fuel rail and throttle body
    Position fuel rail with injectors onto intake manifold and install mounting bolts, torque to specification. Reconnect all fuel injector electrical connectors. Install throttle body with new gasket and torque bolts to specification. Reconnect throttle body electrical connector. Reconnect fuel line to fuel rail until it clicks into place.
    Torque spec

    Fuel Rail Bolts12 Nm (9 lb-ft)

    Throttle Body Bolts10 Nm (7 lb-ft)
16. 16

    Reinstall air intake and refill coolant
    Reconnect breather hose to valve cover. Install air intake tube and tighten clamp at throttle body. Reinstall air filter housing if removed. Refill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level. Reinstall fuel pump fuse.

Reassembly

1. Double-check all electrical connectors, vacuum lines, and hoses are properly connected
2. Verify all bolts are torqued to specification
3. Ensure no tools or rags are left in engine bay
4. Reconnect negative battery cable
5. Reinstall engine cover

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming. Check for fuel leaks at fuel rail connections
• Start engine and check for vacuum leaks by listening for hissing sounds around intake manifold
• Allow engine to reach operating temperature and check for coolant leaks at EGR valve and coolant crossover connections
• Verify smooth idle with no rough running or misfires
• Check coolant level after engine cools and top off if necessary
• Test drive vehicle to verify proper throttle response and no check engine light

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