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Home >> Kia >> 2021 >> Stinger GT-Line, RWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 2.0L >> Turbocharger, Exhaust Manifold And Catalytic Converter >> Repair Procedure >> Removal And Installation

Removal And Installation

  1. Remove the engine cover.

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

  2. Disconnect the negative battery terminal.
  3. Remove the engine room front under cover.

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

  4. Remove the air intake hose.

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

  5. Disconnect the recirculation valve connector (A) and the vacuum hose (B).
    G13423001Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the intercooler inlet hose & pipe assembly (A).

    Tightening torque 

    Nuts (B):

    14, 7 - 19.6 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb.ft)

    Nut (C):

    14.7 - 19.6 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb.ft)

    G13423002Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    1. When disconnect the intercooler inlet hose, pull out the quick connector clamp (A) in the direction of the arrow as shown below.
      G13423003Courtesy of KIA MOTORS AMERICA, INC.
    2. Move the quick connector clamp from position (B) to position (C) as shown below and pull out the quick connector hose.
      G13423004Courtesy of KIA MOTORS AMERICA, INC.
      G13423005Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the turbocharger inlet hose (A).

    Tightening torque: 

    4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft. 43.4 - 60.8 lb.in)

    G13423006Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the heat protector (A).

    Tightening torque: 

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

    G13423007Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the heated oxygen sensor.

    (Refer to Engine Control/Fuel System - "HEATED OXYGEN SENSOR (HO2S) ")

  10. 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)

    G13423008Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the front muffler.

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

  12. Remove the warm-up catalytic converter (WCC) stay (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)

    G13423009Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the RH hood sealing cover (A).
    G13423010Courtesy of KIA MOTORS AMERICA, INC.
  14. 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)

    G13423011Courtesy of KIA MOTORS AMERICA, INC.
    G13423012Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the turbocharger water feed pipe & hose (A).

    Tightening torque: 

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

    G13423013Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the oil feed pipe (A).

    Tightening torque: 

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

    G13423014Courtesy of KIA MOTORS AMERICA, INC.

    Tightening torque: 

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

    G13423015Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the turbocharger water drain hose (A).
    G13423016Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the turbocharger oil drain pipe (A)

    Tightening torque: 

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

    G13423017Courtesy of KIA MOTORS AMERICA, INC.
  19. Remove the turbo manifold module stay (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)

    G13423018Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the turbo manifold module (A).

    Tightening torque: 

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

    G13423019Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Always use the new turbo manifold module gasket.
    • Always use the new turbo manifold module nuts.
    • 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 care full the oil feed pipe & hose not to damage. (bent, crushed, torn or cracked).
    • 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
    G13423020Courtesy of KIA MOTORS AMERICA, INC.
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