Kia Optima: Exhaust Manifold. Repair procedures
Removal and Installation
| 1. |
Remove the engine cover. |
| 2. |
Disconnect the battery negative
terminal.
Tightening torque4.0 ~
6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
|
|
| 3. |
Disconnect the oxygen sensor
connector (A) and then remove the exhaust manifold heat protectors (B).
Tightening torque :7.8
~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
|
|
Check that engine is cool enough to work. |
|
| 4. |
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)
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|
| 5. |
Remove the sub frame (A). (Refer
to SS group)
|
| 6. |
Disconnect the turbocharger water
feed hose (A) and the water darin hose (B).
|
| 7. |
Remove the turbocharger stay
(A) and then disconnect the oil drain pipe (B) and gasket.
Tightening torque :Bolts
(C) : 49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)
Bolts (D) : 18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)
Bolts (E) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
|
|
When installing, clean the gasket surface and replace the oil drain
pipe gasket with new one. |
|
| 8. |
Disconnect the oil feed pipe
(A) and tnen remove the turbo manifold module (B).
Tightening torqueOil 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)
|
|
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.
|
|
When installing, be sure the eye bolt o-rings are completely seated
in both hole of oil feed pipe. |
|
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.
|
| 9. |
Remove the turbo manifold module
gasket (A).
|
| 10. |
Installation is reverse order
of removal.
| •
|
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 ful the oil feed pipe & hose
not to damage.(bent, crushed, torn or cracked). |
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|
Components
1. Hear protector
2. EWGA(Electric Waste Gate Actuator)
3. C-ring
4. Turbo manifold module
5. Turbocharger stay
6. Trubo adapter gasket
7. Turbo ad ...
Components
1. Turbine housing
2. Turbine inlet
3. Turbine outlet
4. Compressor housing
5. Compressor inlet
6. Compressor outlet
7. Center housing
8 ...
Exhaust Manifold. Components and Components Location
Turbo Charger. Components and Components Location