Kia Optima Hybrid: Intake And Exhaust System / Exhaust Manifold Repair procedures

Removal and Installation
1.
Remove the engine cover.
2.
Disconnect the battery negative terminal.

Tightening torque:
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

3.
Disconnect the oxygen sensor connectors (A).

4.
Remove the front muffler (A).

Tightening torque:
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

5.
Using the SST (09392-2H100) (A), remove the front oxygen sensor (B) and the remove the exhaust manifold heat protector (C).

Tightening torque :
Oxygen sensor :
39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2lb-ft)
Heat protector bolts :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

6.
Remove the driveshaft heat protector (A).

7.
Remove the exhaust manifold stay (A).

Tightening torque :
M8 bolts: 18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)
M10 bolts: 51.9 ~ 57.8.m (5.3 ~ 5.9kgf.m, 38.3 ~ 42.6lb-ft)

8.
Remove the engine hanger and cam position sensor cover (A).

9.
Remove the exhaust manifold (A) with the gasket (B).

Tightening torque
49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.7lb-ft)

   
When installing, replace with a new gasket.
When installing the intake manifold, tighten the nuts with pre-torque first, and then tighten the nuts with specified torque in the sequence shown.

10.
Installation is reverse order of removal.
Exhaust Manifold Components and Components Location

Components 1. Heat protector2. Exhaust manifold3. Exhaust manifold gasket4. Exhaust manifold stay ...

Muffler Components and Components Location

Components 1. Front muffler2. Catalytic converter3. Center muffler4. Main muffler5. Gasket6. Hanger ...

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