Removal And Installation

CAUTION: To prevent scalding by the hot exhaust parts, wait until the engine cools down to room temperature.

NOTE:

Use fender covers to avoid damaging painted surfaces.
When handling the metal gasket, be careful not to fold or damage the surface.
To avoid damage, disconnect the wiring connectors carefully.
Replace all gaskets with new ones. Do not reuse.

Disconnect the battery negative terminal.
Remove the engine cover.
(Refer to " Removal And Installation ")
Remove the air cleaner assembly.
(Refer to " Removal and Installation ")
Remove the battery.
(Refer to " Removal ")
Disconnect the Engine Control Module (ECM).
(Refer to " Removal ")
Remove the battery tray.
(Refer to " Removal ")
Remove the engine room under cover.
(Refer to " Removal And Installation ")
Drain engine coolant by loosening the drain plug.
(Refer to " Replacement And Air Bleeding ")
Remove the front muffler.
(Refer to " Front Muffler ")
Disconnect the engine wiring connectors and harness clamps around the exhaust manifold and then connector brackets and wiring protector.
Tightening torque:

7.8 - 9.8 N.m (0.8 -1.0 kgf.m, 5.8 - 7.2 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

Courtesy of KIA MOTORS AMERICA, INC.

Remove the intercooler inlet hose and pipe.

Disconnect the main wiring protector (A).

Disconnect the connector (B), in the intercooler inlet pipe.

G13833528

Courtesy of KIA MOTORS AMERICA, INC.

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)

Clamp 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)

G13833529

Courtesy of KIA MOTORS AMERICA, INC.

Remove the catalytic converter (WCC) upper bracket (A).
Tightening torque:

49 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.1 - 39.8 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the catalytic converter (WCC) upper bracket, tighten the bolts with the torque in the sequence shown.

Fig 1: Catalytic Converter (WCC) Upper Bracket Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Remove the catalytic converter (WCC) lower bracket (A).
Tightening torque:

49 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.1 - 39.8 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: When installing the catalytic converter (WCC) lower bracket, tighten the bolts with the specified torque in the sequence shown.

Fig 2: Catalytic Converter (WCC) Lower Bracket Bolts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.
Remove the EGR cooler pipe mounting bolt and nut (A).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
Remove the catalytic converter (WCC) (A).
Tightening torque:

35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26 - 30.4 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the turbocharger outlet hose (A) and then remove turbocharger water outlet pipe (B).
Tightening torque:

Pipe bracket bolt:

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

Pipe bolt:

26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.
- When installing turbocharger water inlet hose and pipe, check that the eye bolt gasket is installed.
- Always use a new eye bolt gaskets.
Remove the turbocharger heat protector (A).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
Remove the turbocharger water inlet hose and pipe (A).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- When installing turbocharger water inlet hose and pipe, check that the eye bolt gasket is installed.
- Always use a new eye bolt gaskets.
Remove the oil drain pipe (A).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
Remove the oil feed pipe (A).
Tightening torque:

Pipe bracket 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)

Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- When installing oil feed pipe, check that the eye bolt gasket is installed.
- Always use a new eye bolt gaskets.
Remove the exhaust manifold heat protector (A).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the EGR cooler hose (A).

Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the breather hose (A).

Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the differential pressure sensor hoses (A) and then remove the pipe mounting bolt (B).
Tightening torque:

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

Courtesy of KIA MOTORS AMERICA, INC.
Remove the turbo manifold module (A) with gasket.
Tightening torque:

49 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.1 - 39.8 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Always use a new turbo manifold module gasket.
Install in the reverse order of removal.
NOTE: When install the turbo manifold module, attach the nut in the sequence shown in the image below and tighten it completely with the torque prescribed.

Fig 3: Exhaust Manifold Nuts Tightening Sequence
Courtesy of KIA MOTORS AMERICA, INC.