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Home >> Kia >> 2021 >> K5 LXS, FWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 1.6L >> EGR Cooler >> Repair Procedures >> Removal And Installation

Removal And Installation

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

    (Refer to " Removal And Installation  ") 

  3. Remove the air cleaner assembly.

    (Refer to " Removal and Installation  ") 

  4. Remove the battery.

    (Refer to " Removal  ") 

  5. Remove the Engine Control Module (ECM).

    (Refer to " Removal  ") 

  6. Remove the battery tray.

    (Refer to " Removal  ") 

  7. Remove the engine room under cover.

    (Refer to " Removal And Installation  ") 

  8. Drain engine coolant by loosening the drain plug.

    (Refer to " Replacement And Air Bleeding  ") 

  9. Remove the front muffler.

    (Refer to " Front Muffler  ") 

  10. Remove the intercooler inlet hose and pipe.
    1. Disconnect the main wiring protector (A).
    2. Disconnect the connector (B) and the intercooler inlet pipe.
      G13833552Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the intercooler inlet hose and pipe (A).

    Tightening Torque: 

    Mounting bolt:

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

    Clap bolt:

    4.9 - 6.7 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft, 43.4 - 60.8 lb.in)

    G13833553Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the catalytic converter (WCC).

    (Refer to  Removal And Installation   ) 

  12. Disconnect the turbocharger water inlet hose (A).
    G13833554Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the EGR cooler hose A (A).
    G13833555Courtesy of KIA MOTORS AMERICA, INC.
  14. Disconnect the EGR temperature sensor connector (A).
    G13833556Courtesy of KIA MOTORS AMERICA, INC.
  15. Disconnect the EGR cooler outlet hose (A).
    G13833557Courtesy of KIA MOTORS AMERICA, INC.
  16. Disconnect the EGR control valve connector (A).
    G13833558Courtesy of KIA MOTORS AMERICA, INC.
  17. Remove the EGR cooler hose (A).
    G13833559Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the EGR cooler and EGR valve (A).

    Tightening torque: 

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

    G13833560Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the EGR control valve.

    (Refer to  Removal  ) 

  20. Install in the reverse order of removal.
  21. Fill with coolant.

    (Refer to " Replacement And Air Bleeding  ") 

    NOTE: The coolant must be injected according to the integrated thermal management module (ITM) coolant filling method.
  22. Start engine and check for leaks.
  23. Recheck engine coolant level.
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