Kia Sportage: Exhaust Manifold

Components and Components Location

 Components

1. Hear protector
2. EWGA (Electric Waste Gate Actuator)
3. C-ring
4. Turbo manifold module
5. Turbocharger stay
6. Turbo adapter gasket
7. Turbo adapter
8. Turbo adapter heat protector
9. Oil drain pipe assembly
10. Turbocharger oil drain gasket
11. Oil feed pipe & hose assembly
12. Oil drain gasket
13. Exhaust manifold gasket
14. Turbocharger water feed hose
15. Turbocharger water drain hose

Repair procedures

Removal and Installation

1. Remove the engine cover.

2. Disconnect the battery negative terminal (A).

Tightening torque

4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

3. Disconnect the oxygen sensor connector (A).

4. Remove the exhaust manifold heat protectors (A).

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

CAUTION

Check that engine is cool enough to work.

5. Remove the front muffler (A).

Tightening torque: 39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

6. Support the sub frame (A) with a floor jack, and then remove the sub frame mounting bolts and nuts.

Tightening torque: 176.5 ~ 196.1 N.m (18.0 ~ 20.0 kgf.m, 130.2 ~ 144.7 lb-ft)

NOTE

• After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
• Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.

7. Disconnect the turbocharger water feed hose (A) and the water drain hose (B).

8. Remove the turbocharger stay (A) and then disconnect the oil drain pipe (B) and gasket.

Tightening torque:

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

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

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

NOTE

When installing, clean the gasket surface and replace the oil drain pipe gasket with new one.

9. Disconnect the oil feed pipe (A) and then remove the turbo manifold module (B).

Tightening torque

Oil feed pipe eye bolt: 11.8 ~ 17.7N.m (1.2 ~ 1.8kgf.m, 8.7 ~ 13.0lb-ft)

Turbo manifold module nuts: 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.7lb-ft)

CAUTION

When installing the oil feed pipe & hose, make sure the stopper (A) don't touch the compressor housing.

Be careful not to bend or crush the pipe & hose.

NOTE

When installing, be sure the eye bolt о-rings are completely seated in both hole of oil feed pipe.

NOTE

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.

10. Remove the turbo manifold module gasket (A).

11. Installation is reverse order of removal.

NOTE

• Always use the new turbo manifold module and turbo adapter gaskets when replacing.
• Always use a new turbocharger nuts and, exhaust manifold nuts when it is removed.
• 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 fill the oil feed pipe & hose not to damage. (bent, crushed, tom or cracked).

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