Hyundai Kona: Intake and Exhaust System / Exhaust Manifold Repair procedures

Removal and Installation
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
3.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
4.
Loosen the drain plug and drain the coolant and remove the radiator cap to speed draining.
(Refer to Cooling System - "Coolant")
5.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
6.
Remove the battery.
(Refer to Engine Electrical System - "Battery")
7.
Remove the engine control module (ECM).
(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
8.
Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
9.
Remove the intercooler inlet hose and pipe.
(1)
Remove the intercooler inlet hose (A).
Tightening torque :
4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

  
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The groove of hose must be in line with the protrusion of the pipe or turbocharger.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
(2)
Disconnect the intercooler inlet hose (A) from the turbocharger and remove the intercooler inlet pipe (B).
Tightening torque
Clamp : 4.9 - 6.9 N.m(0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)
Mounting bolt : 18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

  
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The marking of hose must be in line with the stopper of the throttle body.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
10.
Remove the WGT control actuator (EWGA) connector (A).

11.
Remove the turbo charger water hose (A).

12.
Remove the turbo charger water pipes (A).
Tightening torque
Flange Bolt :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
Eye Nut :
26.4 - 32.3 N.m (2.7- 3.3 kgf.m, 19.5 - 32.3 lb-ft)

13.
Remove the front oxygen sensor connector (A) .

14.
Remove the warm-up catalytic converter (WCC) stay A (A).
Tightening torque :
39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb-ft)

15.
Remove the turbo charger oil drain pipe (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

16.
Remove the warm-up catalytic converter (WCC) stay B (A).
Tightening torque :
49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.1 - 39.7 lb-ft)

17.
Remove the Warm-up catalytic converter (WCC) (A).
Tightening torque :
35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

18.
Remove the turbo charger oil feed pipe (A).
Tightening torque
M8 Bolt : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
Eye Bolt : 11.8 - 17.7 N.m (1.2 - 1.8 kgf.m, 8.7 - 13.0 lb-ft)

19.
Remove the turbo charger module heat protector (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

20.
Remove the engine mounting support bracket .
(Refer to Engine and Transaxle Assembly - "Engine Mounting")
21.
Remove the turbo charger module (A).
Tightening torque :
35.3 - 41.2 N.m (3.6 - 4.2 kgf.m, 26.0 - 30.4 lb-ft)

22.
Remove the turbo manifold module gasket (A).

  
When installing, you should assemble it toward the coating side (black).
When installing, temporarily tighten the nut in picture order and completely tighten the bolt as specified torque in order.

23.
Install in the reverse order of removal.
  
When installing, replace with a new gasket.
If the oil feed pipe and hose is damaged, the turbocharger could be damaged because turbocharger oil supply is not good. Be careful to not crush.
Exhaust Manifold Components and components location
Components 1. Turbo manifold gasket 2. Turbo manifold module 3. Warm-up catalytic converter (WCC) 4. Warm-up catalytic converter (WCC) gasket 5. Oil feed p ...

Intercooler Components and components location
Components 1. Intercooler 2. Intercooler air guard 3. Intercooler inlet hose 4. Intercooler inlet pipe 5. Intercooler outlet hose 6. Intercooler outlet ...

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