Removal And Installation

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

Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "ENGINE COVER ")
Disconnect the battery negative terminal.
Remove the air cleaner.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Remove the intercooler inlet pipe & hose assembly.
(Refer to Intake and Exhaust System - "INTERCOOLER ")
Disconnect the oxygen sensor connectors (A).

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Remove the exhaust upper heat protector bolt (A).
Tightening Torque:

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

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CAUTION: Check that engine is cool enough to work.
Remove the turbocharger heat protector (A).
Tightening Torque:

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

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Intake & Exhaust System-Turbocharger & Exhaust Manifold - REPAIR PROCEDURES
Remove the heated oxygen sensor from the warm-up catalytic converter (WCC).
(Refer to Engine Control/Fuel System - "HEATED OXYGEN SENSOR (HO2S) ")
Remove the warm-up catalytic converter (WCC) heat protector (A).
Tightening Torque:

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

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Remove the front muffler.
(Refer to Intake and Exhaust System - "MUFFLER ")
Remove the warm-up catalytic converter (WCC) bracket (A).
Tightening Torque:

Bolts (B):

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

Bolts (C):

52.0 - 57.9 N.m (5.3 - 5.9 kgf.m, 38.3 - 42.7 lb.ft)

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Remove the warm-up catalytic converter (WCC) (A) and gasket.
Tightening Torque:

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

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Remove the driveshaft mounting bracket (A).
Tightening Torque:

49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb.ft)

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Disconnect the oil drain pipe (A), and then remove the oil feed pipe (B).
Tightening Torque

Bolts & Nuts:

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

Eye bolt:

11.8 - 17.6 N.m (1.2 - 1.8 kgf.m, 8.7 - 13.0 lb.ft)

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NOTE:
- 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.
- When installing, be sure the eye bolt o-rings are completely seated in both hole of oil feed pipe.
- When installing, clean the gasket surface and replace the oil drain pipe gasket with new one.
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Remove the turbocharger water drain hose (A), and then remove the lower heat protector (B).
Tightening Torque:

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

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Disconnect the turbocharger water feed hose (A) and the electric waste gate actuator (EWGA) connector (B).

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Remove the turbo manifold module.
Tightening Torque:

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

Courtesy of KIA MOTORS AMERICA, INC.

Courtesy of KIA MOTORS AMERICA, INC.

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 1: Exhaust Manifold Nuts Tightening Sequence
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Remove the turbo charger manifold gasket (A).

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Remove the exhaust upper heat protector (A).
Tightening Torque:

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

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Remove the water feed pipe (A) and drain pipe (B).
Tightening Torque:

26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.7 lb.ft)

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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).