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Home >> Hyundai >> 2018 >> Kona Limited, FWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 1.6L >> Exhaust Manifold And Catalytic Converter >> Repair Procedures >> Removal And Installation

Removal And Installation

  1. Disconnect the battery negative terminal.
  2. Remove the engine cover.

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

  3. Remove the engine room under cover.

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

  4. Loosen the drain plug and drain the coolant and remove the radiator cap to speed draining.

    (Refer to Cooling System - "COOLANT ")

  5. Remove the air duct and air cleaner assembly.

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

  6. Remove the battery.

    (Refer to Engine Electrical System - "BATTERY ")

  7. Remove the engine control module (ECM).

    (Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE (ECM) ")

  8. Remove the front muffler.

    (Refer to Intake and Exhaust System - "MUFFLER ")

  9. Remove the intercooler inlet hose and pipe.
    1. Remove the intercooler inlet hose (A).

      Tightening torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

      G12596311Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The groove of hose must be in line with the protrusion of the pipe or turbocharger.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
    2. Disconnect the intercooler inlet hose (A) from the turbocharger and remove the intercooler inlet pipe (B).

      Tightening torque 

      Clamp: 4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

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

      G12596312Courtesy of HYUNDAI MOTOR AMERICA
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The marking of hose must be in line with the stopper of the throttle body.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  10. Remove the WGT control actuator (EWGA) connector (A).
    G12596313Courtesy of HYUNDAI MOTOR AMERICA
  11. Remove the turbo charger water hose (A).
    G12596314Courtesy of HYUNDAI MOTOR AMERICA
  12. Remove the turbo charger water pipes (A).

    Tightening torque 

    Flange Bolt:

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

    Eye Nut:

    26.4 - 32.3 N.m (2.7- 3.3 kgf.m, 19.5 - 32.3 lb-ft)

    G12596315Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the front oxygen sensor connector (A).
    G12596316Courtesy of HYUNDAI MOTOR AMERICA
  14. Remove the warm-up catalytic converter (WCC) stay A (A).

    Tightening torque: 

    39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb-ft)

    G12596317Courtesy of HYUNDAI MOTOR AMERICA
  15. Remove the turbo charger oil drain pipe (A).

    Tightening torque: 

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

    G12596318Courtesy of HYUNDAI MOTOR AMERICA
  16. Remove the warm-up catalytic converter (WCC) stay B (A).

    Tightening torque: 

    49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.1 - 39.7 lb-ft)

    G12596319Courtesy of HYUNDAI MOTOR AMERICA
  17. Remove the Warm-up catalytic converter (WCC) (A).

    Tightening torque: 

    35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

    G12596320Courtesy of HYUNDAI MOTOR AMERICA
  18. Remove the turbo charger oil feed pipe (A).

    Tightening torque 

    M8 Bolt: 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

    Eye Bolt: 11.8 - 17.7 N.m (1.2 - 1.8 kgf.m, 8.7 - 13.0 lb-ft)

    G12596321Courtesy of HYUNDAI MOTOR AMERICA
  19. Remove the turbo charger module heat protector (A).

    Tightening torque: 

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

    G12596322Courtesy of HYUNDAI MOTOR AMERICA
  20. Remove the engine mounting support bracket.

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

  21. Remove the turbo charger module (A).

    Tightening torque: 

    35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

    G12596323Courtesy of HYUNDAI MOTOR AMERICA
  22. Remove the turbo manifold module gasket (A).
    G12596324Courtesy of HYUNDAI MOTOR AMERICA
    NOTE:
    • When installing, you should assemble it toward the coating side (black).
    • When installing, temporarily tighten the nut in picture order and completely tighten the bolt as specified torque in order.
      Fig 1: Exhaust Manifold Bolts Tightening Sequence
      G12596325Courtesy of HYUNDAI MOTOR AMERICA
  23. Install in the reverse order of removal.
    NOTE:
    • When installing, replace with a new gasket.
    • If the oil feed pipe and hose is damaged, the turbocharger could be damaged because turbocharger oil supply is not good. Be careful to not crush.
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