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Home >> Kia >> 2016 >> Optima SX Limited >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 85 (Intake & Exhaust System - 1.6L - Optima (Except HEV)) >> Exhaust Manifold And Catalytic Converter >> Repair Procedures >> Removal and Installation

Removal and Installation

WARNING: This page is about a different variant/trim than selected.
  1. Remove the engine cover.

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

  2. Remove the engine room under cover.

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

  3. Drain the engine coolant.

    (Refer to Cooling System - "COOLANT ")

  4. Remove the battery and battery tray.

    (Refer to Engine Electrical System - "BATTERY ")

  5. Remove the air cleaner assembly.

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

  6. Remove the front muffler.

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

  7. Disconnect the front oxygen sensor connector (A).
    Fig 1: Locating Front Oxygen Sensor Connector
    G11823048Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the engine ground cable (A).

    Tightening torque: 

    10.8 - 13.7N.m (1.1 - 1.4 kgf.m, 8.0 - 10.1 lb.ft)

    Fig 2: Locating Engine Ground Cable
    G11823049Courtesy of KIA MOTORS AMERICA, INC.
  9. Disconnect the electric waste gate actuator (EWGA) extension connector (A).
  10. Remove the intake pipe stay (B).

    Tightening torque 

    M8 Bolts:

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

    M10 Bolt:

    29.4 - 34.3 N.m (3.0 - 3.5kgf.m, 21.6 - 25.3 lb.ft)

  11. Remove the intake pipe (C) and gasket.

    Tightening torque 

    Bolts:

    29.4 - 39.2 N.m (3.0 - 4.0 kgf.m, 21.6 - 28.9 lb.ft)

    Nut:

    35.3 - 41.1 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.3 lb.ft)

    Fig 3: Removing Intake Pipe Stay And Intake Pipe
    G11823050Courtesy of KIA MOTORS AMERICA, INC.
  12. Remove the turbo charger water pipe & hose (A).

    Tightening torque 

    Flange Bolt:

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

    Eye Bolt:

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

  13. Remove the turbo manifold module heat protector (B).

    Tightening torque: 

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

    Fig 4: Removing Turbo Manifold Module Heat Protector
    G11823051Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the catalytic converter (A).

    Tightening torque: 

    35.3 - 41.1 N.m (3.6 - 4.2 kgf.m, 20.0 - 30.3 lb.ft)

    Fig 5: Locating Catalytic Converter
    G11823052Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the turbo charger oil feed pipe (A).

    Tightening torque 

    M6 Bolts:

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

    Eye Bolt:

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

    Fig 6: Removing Turbo Charger Oil Feed Pipe
    G11823053Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When installing, completely remove the oil from assembly part and be careful not to enter any dust.
    • When installing the eye bolt, be careful to not contact with the stopper to the compressor housing.
  16. 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)

    Fig 7: Removing Turbo Charger Oil Drain Pipe
    G11823054Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing, completely remove the oil from assembly part.
  17. Remove the turbo charger stay (A).

    Tightening torque: 

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

    Fig 8: Removing Turbo Charger Stay Tightening Sequence
    G11823055Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing, temporarily tighten the bolt in picture order and completely tighten the bolt as specified torque in order.
  18. Remove the engine mounting support bracket.
    1. Put a jack under the oil pan.
      NOTE: Place a wooden block between the jack and the oil pan to prevent damage to the oil pan.
    2. Remove the engine mounting support bracket (A).

      Tightening torque 

      Nut (B): 88.3 - 13.7 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb.ft)

      Bolt and nuts (C): 58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.4 - 54.2 lb.ft)

      Fig 9: Removing Engine Mounting Support Bracket
      G11823056Courtesy of KIA MOTORS AMERICA, INC.
    3. Lower the slightly using the jack to obtain space for removing the turbo manifold module.
  19. Remove the turbo manifold module (A) and gasket (B).

    Tightening torque: 

    35.3 - 41.1 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.3 lb.ft)

    Fig 10: Locating Turbo Manifold Module And Gasket
    G11823057Courtesy of KIA MOTORS AMERICA, INC.
    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 11: Exhaust Manifold Bolts Tightening Sequence
    G11823058Courtesy of KIA MOTORS AMERICA, INC.
  20. 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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