Repair Procedures: Installation

Install the oil feed pipe (A).
Tightening torque:

Bolt (B):

27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb.ft)

Bolt (C):

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

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Install the oil drain pipe (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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Install the water return hose & pipe (A).
Tightening torque:

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

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Install the water feed hose & pipe (A).
Tightening torque:

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

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Install the turbo manifold module gasket (A).

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NOTE: Always use a new turbo manifold module gasket.
Install the turbo manifold module (A).
Tightening torque:

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

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NOTE:
- Be careful not to crush the oil feed pipe and hose as damaged oil feed pipe and hose may result in damaged turbocharger due to insufficient turbocharger oil supply.
- When installing, pretighten the nuts in the order shown below and then completely tighten the bolts to specified torque in the order below.
  
  Fig 1: Exhaust Manifold Nuts Tightening Sequence
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Remove the oil drain pipe (A) and oil feed pipe (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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Install the tubo charger water feed pipe & hose nuts (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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Install the tubo charger water return hose (A).

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Install the lower 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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Install the 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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Install the warm-up catalytic converter (WCC) gasket (A).

G13664395

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NOTE: Align the gasket hole with the pin, then rotate clockwise to secure the gasket.

G13664396

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Install the clamp (A) on the warm-up catalytic converter (WCC).

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NOTE:
- Always use a new clamp
- If the clamp is spread too much, clamp deformation can occur, spread it to the minimum within the length of the bolt when installing.
Hang the WCC to the hole to secure it before installing.

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Check that the warm-up catalytic converter (WCC) and turbo charger surface is matched.

G13664399

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NOTE: Fit the groove as shown below when installing.

G13664400

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Install the clamp (A).

Tightening torque:

13.5 - 16.5 N.m (1.38 - 1.68 kgf.m, 10.0 - 12.2 lb.ft)

G13664401

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NOTE:

Install the clamp first before installing the other parts.

Align the center of the clamp head in the direction of the arrow of the turbo.

G13664402

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Check the clamp condition.

Normal	Over torque	Under torque
Courtesy of KIA MOTORS AMERICA, INC.	Courtesy of KIA MOTORS AMERICA, INC.	Courtesy of KIA MOTORS AMERICA, INC.

Install the warm-up catalytic converter (WCC) upper stay nut (A).
Tightening torque:

39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb.ft)

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Install the warm-up catalytic converter (WCC) lower stay (A).
Tightening torque:

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

Nuts (C): 39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb.ft)

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Install the front muffler.
(Refer to Intake and Exhaust System - "MUFFLER ")
Install in the reverse order of removal.