Removal and Installation

WARNING: This page is about a different variant/trim than selected.

Remove the engine cover.
(Refer to Engine Mechanical System - "ENGINE COVER ")
Disconnect the battery negative terminal.
Remove the intercooler inlet pipe & hose assembly. (Refer to Intake And Exhaust System - "INTERCOOLER ")
Disconnect the oxygen sensor connector (A).

Fig 1: Locating Oxygen Sensor Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the exhaust manifold heat protector (A), and then remove the bolt (B).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 2: Locating Exhaust Manifold Heat Protector And Bolt
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: Check that engine is cool enough to work.
Remove the air cleaner.
(Refer to Intake And Exhaust System - "AIR CLEANER ")
Remove the front muffler & center muffler.
(Refer to Intake And Exhaust System - "MUFFLER ")
Remove the Warm-up catalytic converter (WCC) heat protector (A).

Fig 3: Locating Warm-Up Catalytic Converter Heat Protector With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Warm-up catalytic converter (WCC) bracket (A).

Fig 4: Locating Warm-Up Catalytic Converter Bracket With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Warm-up catalytic converter (WCC) (A), and gasket (B).

Fig 5: Locating Warm-Up Catalytic Converter And Gasket
Courtesy of HYUNDAI MOTOR AMERICA
Separate the drive shaft fixing bracket (A).

Fig 6: Locating Drive Shaft Fixing Bracket With Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the oil drain pipe (A), and then remove the oil feed pipe (B).
Tightening torque:

Oil drain pipe bolts:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

Oil feed pipe bolts:

11.8 ~ 17.6 N.m (1.2 ~ 1.8 kgf.m, 8.7 ~ 41.1 lb-ft)

Fig 7: Locating Oil Drain Pipe And Oil Feed Pipe
Courtesy of HYUNDAI MOTOR AMERICA

CAUTION: When installing the oil feed pipe & hose, make sure the stopper (A) don"t touch the compressor housing. Be careful not to bend or crush the pipe & hose.

Fig 8: Checking Stopper
Courtesy of HYUNDAI MOTOR AMERICA

NOTE: When installing, be sure the eye bolt o-rings are completely seated in both hole of oil feed pipe.

NOTE: When installing, clean the gasket surface and replace the oil drain pipe gasket with new one.
Remove the turbocharger water drain hose (A), and then remove the exhaust manifold heat protector (B).

Fig 9: Locating Turbocharger Water Drain Hose And Exhaust Manifold Heat Protector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the turbocharger water feed hose (A) and the EWGA (Electric WGT Control Actuator) connector (B).

Fig 10: Locating Turbocharger Water Feed Hose And Electric WGT Control Actuator Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cowl top cover.
(Refer to Body - "COWL TOP COVER ")
Remove the turbo manifold module.
NOTE: When installing, replace with a new gasket. When installing the turbo manifold module, tighten the nuts with pre-torque first, and then tighten the nuts with specified torque in the sequence shown.

Fig 11: Exhaust Manifold Nuts Tightening Sequence
Courtesy of HYUNDAI MOTOR AMERICA
Remove the turbo manifold module gasket (A).

Fig 12: Locating Turbo Manifold Module Gasket
Courtesy of HYUNDAI MOTOR AMERICA
Install in the reverse order of removal.
NOTE:
- Always use the new turbo manifold module and turbo adapter gaskets when replacing.
- Take care whether the oil feed pipe & hose assembly is interfered with turbo manifold module and any surrounding parts.
- If the oil feed pipe & hose is damaged, engine oil is not supplied sufficiently to the turbocharger then it may damage the turbocharger. If the oil drain pipe & hose is damaged and clogged, engine oil is not drained smoothly then it may cause oil leaks from the turbocharger. Be careful the oil feed pipe & hose not to damage. (bent, crushed, torn or cracked).