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Home >> Kia >> 2011 >> Optima SX >> Repair and Diagnosis >> Engine Mechanical >> Intake System And Exhaust System - 2.0L >> Intake Manifold >> Repair Procedures >> Removal And Installation
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Removal And Installation

  1. Remove the engine cover.
  2. Disconnect the battery negative terminal (A).

    Tightening torque 

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

  3. Remove the air duct (B).
    Fig 1: Battery Negative Terminal & Air Duct
    G07385603Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the air cleaner assembly.
    1. Disconnect the breather hose (A), the recirculation hose (B) and brake booster vacuum hose (C).
    2. Disconnect the air intake hose (D) and then remove the air cleaner assembly (E).

      Tightening torque 

      Hose clamp bolt:

      2.9 ~ 4.9 N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6 lb-ft)

      Air cleaner assembly bolts:

      7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

      Fig 2: Air Cleaner Assembly, Breather, Brake Booster & Air Intake Hoses
      G07385604Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the under covers. Refer to ENGINE AND TRANSAXLE ASSEMBLY .
  6. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to drain with speed. Refer to COOLING SYSTEM .
  7. Disconnect the PCV hose (A), the intake OCV (Oil control valve) connector (B) and the OTS (Oil temperature sensor) connector (C).
    Fig 3: PCV Hose, Intake OCV Connector & OTS Connector
    G07385605Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the A/C compressor switch connector (A), the alternator connector (B), the OPS (Oil pressure switch) connector & injector extension connector (C), the knock sensor connector (D), the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (E), the ETC (Electronic throttle control) connector (F) and the vacuum pump connector (G).
    Fig 4: A/C Compressor Switch, Alternator, OPS, Knock, MAPS & ETC Connectors
    G07385606Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the throttle body coolant hoses (A).
    Fig 5: Throttle Body Coolant Hoses
    G07385607Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the oil level gauge (A).
    Fig 6: Oil Level Gauge
    G07385608Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the intake manifold stay (A).

    Tightening torque: 

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

    Fig 7: Intake Manifold Stay
    G07385609Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the intake manifold (A) after disconnecting the vacuum hoses.

    Tightening torque: 

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

    Fig 8: Intake Manifold
    G07385610Courtesy 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 in Fig 9.

    Fig 9: Intake Manifold Bolts & Nuts Tightening Sequence
    G07385611Courtesy of KIA MOTORS AMERICA, INC.
  13. Installation is reverse order of removal.