LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Kia >> 2020 >> Optima Plug-In Hybrid EX >> Repair and Diagnosis >> Engine Mechanical >> Intake And Exhaust System (PHEV) >> Intake Manifold >> Repair Procedures >> Removal And Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removal And Installation

WARNING:
  • Be sure to read and follow the "GENERAL SAFETY INFORMATION & 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.
    G13361277Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the positive crankcase ventilation (PCV) hose (A) and purge control solenoid valve (PCSV) hose (B).
    G13361278Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the purge control solenoid valve (PCSV) bracket (A).
    G13361279Courtesy 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)

    G13361280Courtesy 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)

    G13361281Courtesy 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)

    G13361282Courtesy 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)

    G13361283Courtesy 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)

    G13361284Courtesy 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 And Nuts Tightening Sequence
    G13361285Courtesy of KIA MOTORS AMERICA, INC.
  14. Install in the reverse order of removal.
    NOTE: When installing, replace with new gaskets.
scientia non olet · About LEMON Manuals