Kia Picanto: Intake And Exhaust System / Turbo Manifold Module

Kia Picanto JA 2017-2022 Service & Repair Manual / Engine Mechanical System / Intake And Exhaust System / Turbo Manifold Module

Components and components location
Components

1. Coupler heat protector
2. Warm-up catalytic converter (WCC)
3. Warm-up catalytic converter (WCC) gasket
4. Warm-up catalytic converter (WCC) upper stay
5. Exhaust manifold upper stay
6. Turbocharger manifold
7. Turbocharger manifold gasket


8. Exhaust manifold heat protector
9. Oil drain pipe & hose
10. Oil drain pipe gasket A
11. Oil drain pipe gasket B
12. Oil feed pipe & hose
13. Water feed pipe & hose
14. Water drain pipe & hose

Components

1. Turbine housing
2. Turbine inlet
3. Turbine outlet
4. Compressor housing
5. Compressor outlet
6. Compressor inlet
7. Center housing
8. EWGA (Electric Waste Gate Actuator)
9. Actuator rod

Repair procedures
Removal and Installation
1.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
2.
Drain the engine coolant.
(Refer to Cooling System - "Coolant")
3.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
4.
Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
5.
Disconnect the electric waste gate actuator (EWGA) extension connector (A).

6.
Remove the front oxygen sensor.
(Refer to Engine Control / Fuel System - "Heated Oxygen Sensor (HO2S)")
7.
Disconnect the water hose (A).

8.
Disconnect the turbo charger water drain pipe hose (A).

9.
Remove the coupler heat protector (A) and water drain pipe (B)
Tightening torque
Heat protector mounting bolt :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)
(If equipped with a cap, tighten it until the cap is removed.)
Eye bolt :
26.4 - 32.3 N·m (2.7 - 3.3 kgf·m, 19.5 - 32.3 lb·ft)Pipe mounting
Bolt :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

10.
Remove the exhaust manifold stay (A).
Tightening torque :
39.2 - 44.1 N·m (4.0 - 4.5 kgf·m, 28.9 - 32.5 lb·ft)

11.
Remove the warm-up catalytic converter (WCC) upper stay (A) and then remove the warm-up catalytic converter (WCC) (B).
Tightening torque
Warm-up catalytic converter (WCC) :
49.0 - 53.9 N·m (5.0 - 5.5 kgf·m, 36.1 - 39.7 lb·ft)
Warm-up catalytic converter (WCC) upper stay :
18.6 - 23.5 N·m (1.9 - 2.4 kgf·m, 13.7 - 17.4 lb·ft)

12.
Remove the water feed hose & pipe (A) and oil drain pipe (B).
Tightening torque
Water feed pipe :
26.4 - 32.3 N·m (2.7 - 3.3 kgf·m, 19.5 - 32.3 lb·ft)
Oil drain pipe :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

13.
Remove the oil feed pipe (A).
Tightening torque :
11.8 - 17.7 N·m (1.2 - 1.8 kgf·m, 8.7 - 13.0 lb·ft)

14.
Remove the exhaust manifold heat protector (A).
Tightening torque :
9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

15.
Remove the turbo manifold module (A) with the gasket.
Tightening torque :
35.3 - 41.2 N·m (3.6 - 4.2 kgf·m, 26.0 - 30.4 lb·ft)

   
When installing, replace with a new gasket.
Be careful not to crush the oil feed pipe and hose as damaged oil feed pipe and hose may result in damaged turbocharger due to insufficient turbocharger oil supply.
When installing, pretighten the nuts in the order shown below and then completely tighten the bolts to specified torque in the order.

16.
Install in the reverse order of removal.
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.
1.
Check the assembly of the turbocharger and the exhaust fitting (or the after treatment).
Check that a gasket is installed.
Check that mounting bolts (or nuts) are tightened properly.
Check for gas leakage.
Check for any damage, such as crack, on the parts.
Gas leakage caused by lack of gasket or inadequately tightened mounting bolts (or nuts) may cause abnormal engine noise.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) to the specified torque or replace the gasket or damaged parts with new ones if necessary.
2.
Check the assembly of the exhaust manifold and the cylinder head.
Check that a gasket is installed.
Check that the mounting bolts (or nuts) are tightened properly.
Check for gas leakage.
Gas leakage caused by lack of gasket or inadequately tightened mounting bolts (or nuts) may cause abnormal engine noise.
If the cause of the problem is detected, retighten the mounting bolts (or nuts) to the specified torque or install a new gasket if necessary.
3.
Check the turbocharger oil feed pipe & hose and oil drain pipe & hose.
Check that 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) to the specified torque or replace the gasket or damaged parts with new ones if necessary.
4.
Check for oil leakage between center housing and compressor housing.
Check that the mounting bolts are tightened properly.
Check for oil leakage.
Damaged O-ring (gasket) between the center housing and the compressor housing may cause oil leakage.
If an oil leak is detected, replace the turbocharger with a new one.
5.
Check the turbocharger actuator.
Electronic actuator: Check for movement of the actuator rod when a forced actuator operating mode is performed by KDS. (Refer to DTC guide)

Damaged turbocharger actuator may cause lack of engine power and poor acceleration.
If the actuator rod does not move, replace the turbocharger with a new one.
6.
Check the turbocharger compressor wheel.
Check if the compressor wheel is damaged (bent or deformed).
Check that the compressor wheel rotates smoothly.
e.g.

Damaged compressor wheel may cause abnormal noise from the turbocharger and poor acceleration.
If the compressor wheel are damaged or deformed, replace the turbocharger with a new one.
7.
Check the turbocharger turbine wheel.
Check if the turbine wheel is damaged.
Check that the turbine wheel rotates smoothly.
e.g.

Damaged turbine wheel may cause abnormal noise from the turbocharger and poor acceleration.
If the turbine wheel are damaged or deformed, replace the turbocharger with a new one.
If no problem is detected from the turbocharger, check the turbocharger-related parts according to the procedure as follows.
1.
Check the blow-by hose. (Refer to FL group)
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 will increase and engine oil will not be supplied smoothly to the turbocharger, causing damage to the turbocharger and oil leakage.
If the cause of the problem is detected, replace the breather hose or the related parts with new ones.
2.
Check the air intake hose connected to the turbocharger.
Check if the air intake hose is damaged (bent, crushed, detached or torn).
If the cross-section of the hose diminishes as the air intake hose is bent or crushed, intake air to the turbocharger will be reduced and the pressure in front of turbocharger will drop, causing damage to the turbocharger or oil leakage. If the air intake hose is detached or torn, foreign substances may go into the turbocharger causing damage to it.
If the air intake hose is damaged, replace it with a new one.
3.
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 that 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 will be reduced and the pressure in front of turbocharger will drop, causing damage to the turbocharger and oil leakage.
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.
4.
Check the intercooler hoses & pipes.
Check that the intercooler hoses & pipes are connected properly.
Check if the intercooler hoses & pipes are damaged (bent, detached or torn).
Check for any damage, such as crack, on the intercooler pipes.
Check that the clamps are positioned in place.
If the intercooler hoses & pipes are damaged or disconnected, oil leakage may occur from the hoses & pipes and the turbocharger may exceed the permissible speed causing damage to the turbocharger.
If the intercooler hoses & pipes are damaged, replace them with new ones.
   
Use new clamps when replacing the hoses & pipes.
5.
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 causing damage to the turbocharger.
If the intercooler is damaged, replace them with a new one.
   
Use new clamps when replacing the intercooler.
6.
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 will be reduced causing the bearings in the turbocharger to 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.
7.
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 leakage if foreign substances are accumulated on the oil screen.
If the engine oil level is low, amount of engine oil fed to turbocharger will be reduced causing the bearings in the turbocharger to 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 to the turbocharger bearings. Check engine oil for discoloration, water influx, viscosity degradation and oil pressure lowering.
8.
Check the injectors, sensors, etc. (Refer to FL group)
Check that the injectors operate properly.
Check that the sensors, such as the mass air flow sensor (MAFS), intake air temperature sensor (IATS), and boost pressure sensor (BPS), operate properly.
Improper operation of the injectors, sensors, EGR valve, etc. may cause diminished engine power.
If the cause of the problem is detected, replace the related parts with new ones.
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