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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) >> Exhaust Manifold, Turbo Manifold Module And Catalytic Converter >> Repair Procedures >> Removal and Installation

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 bend or damage the surface.
  • To avoid damage, disconnect the wiring connectors carefully.
  • Replace all gaskets with new ones. Do not reuse.
  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. 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)

    G14937135Courtesy of KIA MOTORS AMERICA, INC.
    G14937136Courtesy of KIA MOTORS AMERICA, INC.
  8. 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.
      G14937137Courtesy of KIA MOTORS AMERICA, INC.
    2. Disconnect the inlet hose (A).
      G14937138Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the inlet pipe (A).
    G14937139Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the catalytic converter (WCC) upper bracket (A).

    Tightening torque: 

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

    G14937140Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: When installing the catalytic converter (WCC) upper bracket, tighten the bolts with the torque in the sequence shown.
    G14937141Courtesy of KIA MOTORS AMERICA, INC.
  10. 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)

    G14937142Courtesy 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 1: Catalytic Converter Lower Bracket Bolts Tightening Sequence
    G14937143Courtesy of KIA MOTORS AMERICA, INC.
  11. 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)

    G14937144Courtesy of KIA MOTORS AMERICA, INC.
  12. 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)

    G14937145Courtesy of KIA MOTORS AMERICA, INC.
  13. 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)

    G14937146Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When install the turbocharger water outlet pipe, check the eye bolt gaskets installed it
    • Always use a new eye bolt gaskets.
  14. 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)

    G14937147Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the turbocharger water inlet hose & pipe (A).

    Tightening torque: 

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

    G14937148Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When install the turbocharger water inlet hose & pipe, check the eye bolt gaskets installed it
    • Always use a new eye bolt gaskets.
  16. 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)

    G14937149Courtesy of KIA MOTORS AMERICA, INC.
  17. 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)

    G14937150Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • When install the oil feed pipe, check the eye bolt gaskets are installed
    • Always use a new eye bolt gaskets.
  18. 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)

    G14937151Courtesy of KIA MOTORS AMERICA, INC.
  19. Disconnect the EGR cooler hose (A).
    G14937152Courtesy of KIA MOTORS AMERICA, INC.
  20. Disconnect the breather hose (A).
    G14937153Courtesy of KIA MOTORS AMERICA, INC.
  21. 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)

    G14937154Courtesy of KIA MOTORS AMERICA, INC.
  22. 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)

    G14937155Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Always use a new turbo manifold module gasket.
  23. Install in the reverse order of removal.
    NOTE: When installing, temporarily tighten the nut according to the following procedure and fully tighten it to the specified torque.
Fig 2: Exhaust Manifold And Turbo Manifold Module Nuts Tightening Sequence
G14937156Courtesy of KIA MOTORS AMERICA, INC.
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