Removal And Installation: Removal

CAUTION: Wait until cooling the engine for preventing the scalding by high temperature from the exhaust system.

NOTE:

Use a fender cover to protect the painted surface.
When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
To avoid damage, disconnect the wiring connectors carefully.
The existing gasket should be replaced with a new one.

Disconnect the battery negative (-) terminal.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - " ENGINE COVER ")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "AIR CLEANER ")
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - " ENGINE ROOM UNDER COVER ")
Drain the coolant.
(Refer to Cooling System - " COOLANT ")
Remove the front muffler.
(Refer to Intake and Exhaust System - "MUFFLER ")
Remove the Warm-up Catalytic Converter (WCC).
(Refer to Emission Control System - " CATALYTIC CONVERTER REMOVAL & INSTALLATION ")
Remove the resonator (A) after releasing the clamp.

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Remove the turbocharger water outlet hose (A) after releasing the clamp.

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Remove the turbocharger water inlet hose (A) after releasing the clamp.

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Disconnect the Electric Waste Gate Actuator (EWGA) connector (A).

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Separate the engine wiring (A) after removing the bolt.
Tightening torque:

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

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Remove the elbow pipe bracket (A) after removing the bolt.
Tightening torque:

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

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Separate the intercooler inlet hose (A) after releasing the quick connector.

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Separate the breather hose (A) after releasing the clamp.

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Separate the turbocharger water outlet pipe (B) after removing the bolt (A).

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Remove the oil drain pipe (A) after removing the bolts and nuts.
Tightening torque:

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

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Remove the oil feed pipe (A) after removing the bolts.

Tightening torque

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

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

D: 16.7 - 21.6 N.m (1.7 - 2.2 kgf.m, 12.3 - 15.9 lb.ft)

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NOTE:

Do not reuse the copper washer (A).
When installing, make sure that a new copper washer (A) is installed.

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Remove the exhaust manifold heat protector (A) after removing the bolts.
Tightening torque:

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

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Remove the turbo manifold module (A) with gasket after removing the nuts.
Tightening torque:

49 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb.ft)

Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Do not reuse the turbo manifold module gasket.