Removal And Installation

Remove the engine cover (A).

Fig 1: Identifying Engine Cover
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the battery negative terminal.
Disconnect the oxygen sensor connector (A) and then remove the exhaust manifold heat protectors (B).
Tightening torque:

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

Fig 2: Oxygen Sensor Connector & Exhaust Manifold Heat Protectors
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Check that engine is cool enough to work.
Remove the front muffler (A).
Tightening torque:

39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

Fig 3: Front Muffler
Courtesy of KIA MOTORS AMERICA, INC.
Remove the sub frame (A). Refer to FRONT CROSS MEMBER .

Fig 4: Sub Frame
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Disconnect the turbocharger water feed hose (A) and the water drain hose (B).

Fig 5: Turbocharger Water Feed Hose & Water Drain Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the turbocharger stay (A) and then disconnect the oil drain pipe (B) and gasket.
Tightening torque:

Bolts (C) : 49.0 ~ 53.9 N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8 lb-ft)

Bolts (D) : 18.6 ~ 27.5 N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3 lb-ft)

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

Fig 6: Turbocharger Stay & Oil Drain Pipe
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing, clean the gasket surface and replace the oil drain pipe gasket with new one.
Disconnect the oil feed pipe (A) and then remove the turbo manifold module (B).
Tightening torque

Oil feed pipe eye bolt:

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

Turbo manifold module nuts:

49.0 ~ 53.9 N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.7 lb-ft)

Fig 7: Identifying Oil Feed Pipe & Turbo Manifold Module
Courtesy of KIA MOTORS AMERICA, INC.

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: Oil Feed Pipe Stopper
Courtesy of KIA MOTORS AMERICA, INC.

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

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 in Fig 9.

Fig 9: Exhaust Manifold Nuts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Remove the turbo manifold module gasket (A).

Fig 10: Turbo Manifold Module Gasket
Courtesy of KIA MOTORS AMERICA, INC.
Installation is reverse order of removal.
NOTE:
- Always use the new turbo manifold module and turbo adapter gaskets when replacing.
- Always use a new turbocharger nuts and, exhaust manifold nuts when it is removed.
- 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 not to damage the oil feed pipe & hose. (bent, crushed, torn or cracked).