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Home >> Kia >> 2019 >> Optima SX >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 2.0L (Except HEV) >> Intercooler >> Repair Procedures >> Removal And Installation

Removal And Installation

  1. Remove the engine cover.

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

  2. Remove the air duct.

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

  3. Remove the battery

    (Refer to Engine Electrical System - "BATTERY ")

  4. Remove the air cleaner assembly.

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

  5. Remove the engine room under cover.

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

  6. Disconnect the recirculation valve connector (A) and the vacuum hose (B).
    G12921918Courtesy of KIA MOTORS AMERICA, INC.
  7. 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)

    G12921919Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
  8. Disconnect the boost pressure sensor connector (A).
    G12921920Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the intercooler outlet pipe & hose assembly (B).

    Tightening torque: 

    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.)

    G12921921Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
  10. Remove the front bumper cover.

    (Refer to Body - "FRONT BUMPER COVER ")

  11. Disconnect the wiring clips (A).
    G12921922Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the intercooler upper bracket (A).

    Tightening torque: 

    7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.7 - 8.7 lb.ft)

    G12921923Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the dual air duct (A).

    Tightening torque: 

    7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.7 - 8.7 lb.ft)

    G12921924Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove intercooler assembly (A) from the vehicle.
    G12921925Courtesy of KIA MOTORS AMERICA, INC.
  15. Install in the reverse order of removal.