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Home >> Kia >> 2023 >> Sorento Plug-In Hybrid SX Prestige >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System (PHEV) >> EGR Cooler >> Repair Procedures >> Removal and installation

Removal and installation

  1. Disconnect the battery negative terminal.

    (Refer to Engine Electrical System - "AUXILIARY BATTERY ")

  2. Remove the engine cover.

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

  3. Remove the air cleaner assembly.

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

  4. Remove the engine room under cover.

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

  5. Drain engine coolant by removing the drain plug.

    (Refer to Cooling System - "COOLANT ")

  6. Remove the front muffler.

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

  7. Remove the intercooler inlet hose and pipe.
    1. After removing the main wire protector (A), remove the connector (B) and remove it from the intercooler inlet pipe.
      G14937163Courtesy of KIA MOTORS AMERICA, INC.
    2. Disconnect the intercooler inlet hose (A).
      G14937164Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the intercooler inlet pipe (A).
    G14937165Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the catalytic converter (WCC).

    (Refer to Intake and Exhaust System - "TURBO MANIFOLD MODULE ")

  9. Disconnect the turbocharger water inlet hose (A).
    G14937166Courtesy of KIA MOTORS AMERICA, INC.
  10. Disconnect the EGR cooler hose A (A).
    G14937167Courtesy of KIA MOTORS AMERICA, INC.
  11. Disconnect the EGR temperature sensor connector (A).
    G14937168Courtesy of KIA MOTORS AMERICA, INC.
  12. Disconnect the EGR cooler outlet hose (A).
    G14937169Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the EGR control valve connector (A).
    G14937170Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the EGR gas hose (A).
    G14937171Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the EGR cooler & EGR valve (A).

    Tightening torque: 

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

    G14937172Courtesy of KIA MOTORS AMERICA, INC.
  16. Remove the EGR control valve.

    (Refer to Emission Control System - "ELECTRICAL EGR (EXHAUST GAS RECIRCULATION) SOLENOID VALVE ")

  17. Install in the reverse order of removal.
  18. Fill with coolant.

    (Refer to Cooling system - "COOLANT ")

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