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Home >> Kia >> 2016 >> Optima SX Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 85 (Intake & Exhaust System - 1.6L - Optima (Except HEV)) >> Intercooler >> Repair Procedures >> Removal and Installation

Removal and Installation

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the battery negative (-) terminal.
  2. Remove the air duct and air cleaner assembly.

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

  3. Disconnect the intercooler outlet hose (A).

    Tightening torque: 

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 1: Locating Intercooler Outlet Hose
    G11823060Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the engine room under cover.

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

  5. Remove the intercooler inlet hose & pipe (A).

    Tightening torque 

    Bolts:

    19.6 - 26.4 N.m (2.0 - 2.7 kgf.m, 14.4 - 19.5 lb.ft)

    Clamp:

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 2: Removing Intercooler Inlet Hose And Pipe
    G11823061Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the RCV solenoid valve hose (A).
    Fig 3: Locating RCV Solenoid Valve Hose
    G11823062Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the boost pressure sensor connector (A).
    Fig 4: Locating Boost Pressure Sensor Connector
    G11823063Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the RCV solenoid valve connector (A), and then remove the wiring (B) from the intercooler.
    Fig 5: Locating RCV Solenoid Valve Connector And Intercooler Wiring
    G11823064Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the front bumper.

    (Refer to Body (Interior and Exterior) - "FRONT BUMPER ")

  10. Remove the air guide mounting bolt (A).

    Tightening torque: 

    6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb.ft)

    Fig 6: Removing Air Guide Mounting Bolt
    G11823065Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the intercooler upper mounting bracket (A).

    Tightening torque: 

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

    Fig 7: Removing Intercooler Upper Mounting Bracket
    G11823066Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the intercooler (A).
    Fig 8: Locating Intercooler
    G11823067Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the air guard (A).
    Fig 9: Locating Air Guard
    G11823068Courtesy of KIA MOTORS AMERICA, INC.
  14. Install in the reverse order of removal.
    NOTE:
    • Match the marking part of hose and marking part of throttle body, compressor.
    • Match the pipe stopper and hose marking.
    • When the band part is placed on the position mark of hose, install not to exceed the mark.
    • Tighten until the torque control cap is released. If there is no torque control cap, tighten as specified torque.
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