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Home >> Kia >> 2018 >> Optima Plug-In Hybrid EX >> Repair and Diagnosis >> Engine Mechanical >> Intake And Exhaust System (PHEV) >> Intake Manifold >> Repair Procedures >> Removal And Installation
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Removal And Installation

WARNING:
  • Be sure to read and follow the "GENERAL SAFETY INFORMATION AND CAUTION " before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
  • Be sure to shut off the high voltage circuit according to the "HIGH VOLTAGE SHUTOFF PROCEDURE " before doing any work related with the high voltage system to avoid serious electrical injuries.
  1. Shut off the high voltage circuit.

    (Refer to Engine Mechanical System - "HIGH VOLTAGE SHUT OFF PROCEDURE ")

  2. Remove the engine cover.

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

  3. Remove the air cleaner assembly.

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

  4. Remove the engine room under cover.

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

  5. Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.
    G12352976Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the positive crankcase ventilation (PCV) hose (A) and purge control solenoid valve (PCSV) hose (B).
    G12352977Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the purge control solenoid valve (PCSV) bracket (A).
    G12352978Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the EGR cooler pipe C (A).

    Tightening Torque: 

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

    G12352979Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the electric water pump (EWP) water pipe (A) from the intake manifold.

    Tightening Torque: 

    8.8 - 10.9 N.m (0.9 - 1.1 kgf.m, 6.5 - 8.0 lb.ft)

    G12352980Courtesy of KIA MOTORS AMERICA, INC.
  10. Unfasten the electric throttle body control (ETC) module bolts.

    (Refer to Engine Control/Fuel System - "ELECTRIC THROTTLE BODY CONTROL SYSTEM (ETC) ")

  11. Remove the wiring bracket (A).

    Tightening Torque: 

    9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb.ft)

    G12352981Courtesy of KIA MOTORS AMERICA, INC.
  12. 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)

    G12352982Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the intake manifold (A) with the gasket.

    Tightening Torque: 

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

    G12352983Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing the intake manifold, tighten the bolts and nuts, and then tighten the bolts and nuts to the specified torque in the sequence shown.
    Fig 1: Intake Manifold Bolts & Nuts Tightening Sequence
    G12352984Courtesy of KIA MOTORS AMERICA, INC.
  14. Install in the reverse order of removal.
    NOTE: When installing, replace with new gaskets.
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