Kia Forte: Intake And Exhaust System / Turbocharger & Exhaust Manifold

Kia Forte 2019-2024 (BD) Service Manual / Engine Mechanical System / Intake And Exhaust System / Turbocharger & Exhaust Manifold

Components and components location

Components

1. Turbo manifold gasket
2. Turbo manifold module
3. Catalytic converter
4. Turbo charger coupler & gasket
5. Oil feed pipe & hose assembly
6. Oil drain pipe assembly

7. Turbo manifold module heat protector
8. Turbo charger water pipe & hose assembly
9. Turbo charger stay
10. Intake pipe
11. Intake pipe gasket
12. Intake pipe stay
13.Oil drain pipe gasket

1. Turbine housing
2. Turbine inlet
3. Turbine outlet
4. Compressor housing

5. Compressor inlet
6. Compressor outlet
7. Electric waste gate actuator
8. Electric waste gate actuator rod

Repair procedures

Removal and Installation

1.	Remove the engine cover. (Refer to Engine and Transmission Assembly - "Engine Cover")

2.	Remove the engine room under cover. (Refer to Engine and Transmission Assembly - "Engine Room Under Cover")

3.	Drain the engine coolant. (Refer to Cooling System - "Coolant")

4.	Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")

5.	Remove the air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

6.	Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")

7.	Disconnect the front oxygen sensor connector (A).

Disconnect the engine ground cable (A).

Tightening torque :

10.8 - 13.7N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

9.	Disconnect the electric waste gate actuator (EWGA) extension connector (A).

10.

Remove the intake pipe stay (B).

Tightening torque

M8 Bolts :

18.6 - 23.5 N·m (1.9 - 2.4kgf·m, 13.7 - 17.4 lb·ft)

M10 Bolt :

29.4 - 34.3 N·m (3.0 - 3.5kgf·m, 21.6 - 25.3 lb·ft)

11.

Remove the intake pipe(C) and gasket.

Tightening torque

Bolts :

29.4 - 39.2 N·m (3.0 - 4.0 kgf·m, 21.6 - 28.9 lb·ft)

Nut :

35.3 - 41.1 N·m (3.6 - 4.2 kgf·m, 26.0 - 30.3 lb·ft)

12.

Remove the turbo charger water pipe & hose (A).

Tightening torque

Flange Bolt :

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

Eye Bolt :

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

13.

Remove the turbo manifold module heat protector (B).

Tightening torque :

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

14.

Remove the catalytic converter (A).

Tightening torque :

35.3 - 41.1 N·m (3.6 - 4.2 kgf·m, 20.0 - 30.3 lb·ft)

15.

Remove the turbo charger oil feed pipe (A).

Tightening torque

M6 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)

•	When installing, completely remove the oil from assembly part and be careful not to enter any dust.

•	When installing the eye bolt, be careful to not contact with the stopper to the compressor housing.

16.

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)

When installing, completely remove the oil from assembly part.

17.

Remove the turbo charger stay (A).

Tightening torque :

49.0 - 53.9 N·m (5.0 - 5.5 kgf·m, 36.1 - 39.7 lb·ft)

When installing, temporarily tighten the bolt in picture order and completely tighten the bolt as specified torque in order.

18.

Remove the engine mounting support bracket.

(1)

Put a jack under the oil pan.

Place a wooden block between the jack and the oil pan to prevent damage to the oil pan.

(2)

Remove the engine mounting support bracket (A).

Tightening torque

Nut (B) : 88.3 - 13.7 N·m (9.0 - 11.0 kgf·m, 65.1 - 79.6 lb·ft)

Bolt and nuts (C) : 58.8 - 73.5 N·m (6.0 - 7.5 kgf·m, 43.4 - 54.2 lb·ft)

(3)	Lower the slightly using the jack to obtain space for removing the turbo manifold module.

19.

Remove the turbo manifold module (A) and gasket (B).

Tightening torque :

35.3 - 41.1 N·m (3.6 - 4.2 kgf·m, 26.0 - 30.3 lb·ft)

•	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.

20.

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.

On-vehicle Inspection

Turbocharger Diagnostic Flow

If any problem related with turbocharger, such as lack of engine power, poor acceleration, abnormal engine noise or oil leaks, may occur, check the turbocharger according to the procedure as follows.

Check for assembling of the turbocharger and the exhaust fitting (or the after treatment).

–	Check if a gasket is installed.

–	Check if mounting bolts (or nuts) are tightened properly.

–	Check if there is a gas leak.

–	Check if there is any damage, such as crack, on the parts.

If a gas leak occur as a gasket was not installed or mounting bolts (or nuts) were tightened inadequately, it may cause abnormal engine noise.

If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the gasket or damaged parts with new ones if necessary.

Check for assembling of the turbocharger and the exhaust manifold.

–	Check if a gasket is installed.

–	Check if the mounting bolts (or nuts) are tightened properly.

–	Check if there is a gas leak.

–	Check if there is any damage, such as crack, on the parts.

If a gas leak occur as a gasket was not installed or mounting bolts (or nuts) were tightened inadequately, it may cause abnormal engine noise.

If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the gasket or damaged parts with new ones if necessary.

Check for assembling of the exhaust manifold and the cylinder head.

–	Check if a gasket is installed.

–	Check if the mounting bolts (or nuts) are tightened properly.

–	Check if there is a gas leak.

If a gas leak occur as a gasket was not installed or mounting bolts (or nuts) were tightened inadequately, it may cause abnormal engine noise.

If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or install a new gasket if necessary.

Check the turbocharger oil feed pipe & hose and oil drain pipe & hose.

–	Check if a gasket is installed.

–	Check if the mounting bolts are tightened properly.

–	Check if the clamps are positioned in place.

–	Check if the oil pipes & hoses are damaged (bent, crushed, torn or cracked).

If a gas leak occur as a gasket was not installed or mounting bolts were tightened inadequately, it may cause oil leaks.

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.

If the cause of the problem is detected, retighten the mounting bolts (or nuts) as the specified torque or replace the gasket or damaged parts with new ones if necessary.

Check for oil leaks between center housing and compressor housing.

–	Check if the mounting bolts are tightened properly.

–	Check if there is an oil leak.

If the O-ring (gasket) between the center housing and the compressor housing is damaged, it may cause oil leaks.

If an oil leak is detected, replace the turbocharger with a new one.

Check the setting marks of the turbocharger EWGA rod.

–	Check if the EWGA rod setting mark (A) is aligned in line.

If the setting marks are not aligned in line, the engine performance is changed by an arbitrary tune-up of the turbocharger after delivery.

If the setting marks are not aligned in line, replace the turbocharger with a new one.

Check the turbocharger EWGA.

–	Electric waste gate actuator : Check for movement of the EWGA rod when a forced actuator operating mode is performed by KDS. (Refer to DTC guide)

If the turbocharger EWGA is damaged, it may cause lack of engine power and poor acceleration.

If the EWGA rod does not move, replace the turbocharger with a new one.

Check the turbocharger compressor wheel.

–	Check if the compressor wheel is damaged (bent or deformed).

–	Check if the compressor wheel rotates smoothly. EX)

If the compressor wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.

If the compressor wheel are damaged or deformed, replace the turbocharger with new ones.

Check the turbocharger turbine wheel.

–	Check if the turbine wheel is damaged.

–	Check if the turbine wheel rotates smoothly. EX)

If the turbine wheel are damaged, it may cause abnormal noise from the turbocharger and poor acceleration.

If the turbine wheel are damaged or deformed, replace the turbocharger with new ones.

If any problem is not detected in the turbocharger, check the turbocharger-related parts according to the procedure as follows.

Check the blow-by hose.

–	Check if the breather hose is damaged (bent, clogged).

–	Check if the positive crankcase ventilation (PCV) valve is clogged.

If the breather hose is bent or clogged, the internal pressure in the engine increases then engine oil is not supplied smoothly to the turbocharger. So it may cause damage of the turbocharger and oil leaks.

If the cause of the problem is detected, replace the breather hose or the related parts with new ones.

Check the air intake hose connected to the turbocharger.

–	Check if the air intake hose is damaged (bent, crushed, detached or torn).

If a cross-section of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. If the air intake hose is detached or torn, a foreign substance goes into the turbocharger and causes damage of it.

If the air intake hose is damaged, replace it with a new one.

Check the air cleaner.

–	Check the air cleaner filter for pollution state.

–	Check the air cleaner filter for water influx.

–	Check the air cleaner cover for dirtiness.

–	Check if the air cleaner filter is a genuine part..

If the air cleaner filter is moistened or polluted excessively or a non-genuine part is used, intake air to the turbocharger reduces and the pressure in front of turbocharger drops. So it may cause damage of the turbocharger and oil leaks. .

If the air cleaner filter is moistened or polluted excessively, replace it with a new one.

Replace the air cleaner filter according to the maintenance schedule.

Check the intercooler hoses & pipes.

–	Check if the intercooler hoses & pipes are connected properly.

–	Check if the intercooler hoses & pipes are damaged (bent, detached or torn).

–	Check if there is any damage, such as crack, on the intercooler pipes.

–	Check if the clamps are positioned in place.

If the intercooler hoses & pipes are damaged or disconnected, oil leaks may occur from the hoses & pipes and the turbocharger may exceed the permissible speed then it may cause damage of the turbocharger.

If the intercooler hoses & pipes are damaged, replace them with new ones.

Use new clamps when replacing the hoses & pipes.

Check the intercooler.

–	Check if the intercooler tubes and tanks are damaged (oil leak or crack).

If the intercooler is damaged, the turbocharger may exceed the permissible speed then it may cause damage of the turbocharger.

If the intercooler is damaged, replace them with a new one.

Use new clamps when replacing the intercooler.

Check the engine oil.

–	Check the engine oil level.

–	Check the engine oil for discoloration, water influx and viscosity degradation.

–	Check the engine oil grade.

If the engine oil level is low, amount of engine oil fed to turbocharger reduces then the bearings in the turbocharger may adhere due to insufficient lubrication and cooling.

If the cause of the problem is detected, add or change engine oil.

Change the engine oil according to the maintenance schedule.

Check the engine oil pressure.

–	Engine oil pressure: Check the oil pressure using an oil pressure gauge after removing the oil pressure switch on the cylinder block.

–	Check the engine oil screen in the oil pan if the engine oil level is low. Then check the injectors for gas leaks if foreign substances are accumulated on the oil screen.

If the engine oil level is low, amount of engine oil fed to turbocharger reduces then the bearings in the turbocharger may adhere due to insufficient lubrication and cooling.

If the cause of the problem is detected, add or change engine oil. If foreign substances are accumulated on the oil screen, wash the oil screen and replace the injector’s washer with a new one after checking the injectors for gas leaks. Check the engine oil-related parts, such as oil pump, if necessary.

As the turbocharger rotates at high speed of 100,000 rpm or above, deterioration of engine oil can cause damage of the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and oil pressure lowering.

Check the injectors, sensors, EGR valve, etc. (Refer to FL group)

–	Check if the injectors operate properly.

–	Check if the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), boost pressure sensor (BPS), operate properly.

–	Check if the exhaust gas recirculation (EGR) valve operates properly.

If the injectors, sensors, EGR valve and etc. don’t work properly, it may cause lack of engine power.

If the cause of the problem is detected, replace the related parts with new ones.

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