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Home >> Kia >> 2016 >> Optima SX >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake & Exhaust System - 2.0L - Optima (Except HEV) >> Intake Manifold >> Repair Procedures >> Removal and Installation

Removal and Installation

  1. Disconnect the battery negative terminal.
  2. Remove the air duct.

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

  3. Disconnect the recirculation valve connector (A) and the vacuum hose (B).
    Fig 1: Disconnecting Recirculation Valve Connector And Vacuum Hose
    G11825608Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the intercooler inlet pipe & hose assembly (A).

    Tightening torque 

    Hose clamp bolt:

    4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft)

    (If equipped with a cap, tighten it until the cap is removed.)

    Pipe mounting Bolt:

    14.7 - 19.5 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb.ft)

    Fig 2: Removing Intercooler Inlet Pipe & Hose Assembly
    G11825609Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
  5. Disconnect the boost pressure sensor connector (A).
    Fig 3: Disconnecting Boost Pressure Sensor Connector
    G11825610Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the intercooler outlet pipe & hose assembly (A).

    Tightening torque: 

    4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft)

    Fig 4: Removing Intercooler Outlet Pipe & Hose Assembly
    G11825611Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
  7. Remove the engine room under cover.

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

  8. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed.

    (Refer to Cooling system - "COOLANT ")

  9. Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C).
    Fig 5: Disconnecting PCV Hose, Intake Oil Control Valve Connector And Oil Temperature Sensor Connector
    G11825612Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the wiring connectors and harness clamps and remove the connector brackets around the intake manifold.
    Fig 6: Disconnecting Wiring Connectors And Harness Clamps
    G11825613Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the throttle body coolant hoses (A).
    Fig 7: Disconnecting Throttle Body Coolant Hoses
    G11825614Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the oil level gauge (A).
    Fig 8: Removing Oil Level Gauge
    G11825615Courtesy of KIA MOTORS AMERICA, INC.
  13. 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 9: Removing Intake Manifold Stay
    G11825616Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the intake manifold (A) after disconnecting the vacuum hoses.

    Tightening torque: 

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

    Fig 10: Removing Intake Manifold
    G11825617Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When installing, replace with new gaskets.
    • When installing the intake manifold, tighten the bolts and nuts with pre-torque first, and then tighten the bolts and nuts with specified torque in the sequence shown.
    Fig 11: Intake Manifold Bolts Tightening Sequence
    G11825618Courtesy of KIA MOTORS AMERICA, INC.
  15. Install in the reverse order of removal.
NOTE: After replacing the intake manifold, be sure to delete the previous VCMA additive value by performing the "resetting adaptive values" procedure using KDS/GDS.
(Refer to Engine Control/Fuel System - "VARIABLE CHARGE MOTION ACTUATOR (VCMA) ")
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