Kia Optima Hybrid: Intake And Exhaust System / Intake 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.
Remove the air cleaner assembly. (Refer to Engine and transaxle assembly in this group)
4.
Remove the under cover. (Refer to Engine and transaxle assembly in this group)
5.
Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.
(1)
The intake oil control valve (OCV) connector (A) .

(2)
The oil pressure switch (OPS) connector (A), the A/C compressor switch connector (B) and the hybrid searter generator (HSG) sensor connector (C).

(3)
The injector connectors (A).

(4)
The electronic throttle control (ETC) connector (A), the manifold absolute pressure sensor (MAPS) & intake air temperature sensor (IATS) connector (B), the knock sensor connector (C) and the intake camshaft position sensor (CMPS) connector (D).

6.
Remove the radiator upper hose clip (A).

7.
Disconnect the positive crankcase ventilation (PCV) hose (A).

8.
Remove the delivery pipe & injector assembly (A). (Refer to FL group)

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

9.
Disconnect the purge control solenoid valve (PCSV) hose (A).

10.
Disconnect the throttle body coolant hoses (A). (if equipped)

11.
Remove the oil level gauge (A).

12.
Remove the electric water pump (EWP) inlet pipe mounting bolts (A).

13.
Remove the intake manifold stay (A).

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

14.
Remove the intake manifold (A) with the gasket.

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

   
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.

15.
Installation is reverse order of removal.
Intake Manifold Components and Components Location

Components 1. Intake manifold assembly 2. Intake manifold gasket3. ETC (Electronic throttle body)4. Intake manifold stay ...

Exhaust Manifold Components and Components Location

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

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