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Kia Sorento: EGR Cooler Repair procedures - Intake And Exhaust System - Engine Mechanical SystemKia Sorento: EGR Cooler Repair procedures

Kia Sorento (MQ4, 2021-2026) Service Manual / Engine Mechanical System / Intake And Exhaust System / EGR Cooler Repair procedures

Removal and installation
EGR cooler
1.
Disconnect the battery negative ( - ) terminal.
2.
Remove the engine cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
3.
Remove the air duct and air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
4.
Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
5.
Drain engine coolant by loosening the drain plug.
(Refer to Cooling System - "Coolant")
6.
Remove the front muffler.
(Refer to Intake And Exhaust System - "Muffler")
7.
Remove the water inlet pipe.
(Refer to Cooling System - "ITM")
8.
Remove the exhaust manifold.
(Refer to Intake And Exhaust System - "Exhaust Manifold")
9.
Remove the EGR cooler (A).
Tightening torque:
18.6 - 23.5 N·m (1.9 - 2.4 kgf·m , 13.7 - 17.4 lb·ft)

Engine Mechanical System — Intake And Exhaust System / EGR Cooler / Repair procedures / Removal and installation illustration

Note
Do not reuse the EGR cooler gasket.
10.
Install in the reverse order of removal.
Note
When installing the EGR cooler, tighten the bolts with pre-torque first and then tighten the bolts with the specified torque as the sequence shown.

Engine Mechanical System — Intake And Exhaust System / EGR Cooler / Repair procedures / Removal and installation illustration

11.
Fill engine coolant.
(Refer to Cooling System - "Coolant")
Note
The coolant must be injected according to the integrated thermal management module (ITM) coolant filling method.
EGR cooler pipe C
1.
Disconnect the battery negative ( - ) terminal.
2.
Remove the engine cover.
(Refer to Engine And Transaxle Assembly - "Engine Cover")
3.
Remove the air cleaner assembly.
(Refer to Intake And Exhaust System - "Air Cleaner")
4.
Remove the engine room under cover.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
5.
Drain engine coolant by loosening the drain plug.
(Refer to Cooling System - "Coolant")
6.
Remove the integrated thermal management module (ITM).
(Refer to Cooling System - "Integrated Thermal Management Module (ITM)")
7.
Remove the EGR cooler pipe C (A).
Tightening torque:
Bolt B: 7.8 - 9.8 N·m (0.8 - 1.0 kgf·m , 5.8 - 7.2 lb·ft)
Bolt C: 18.6 - 23.5 N·m (1.9 - 2.4 kgf·m , 13.7 - 17.4 lb·ft)
Nut D: 18.6 - 23.5 N·m (1.9 - 2.4 kgf·m , 13.7 - 17.4 lb·ft)

Engine Mechanical System — Intake And Exhaust System / EGR Cooler / Repair procedures / Removal and installation illustration

Engine Mechanical System — Intake And Exhaust System / EGR Cooler / Repair procedures / Removal and installation illustration

8.
Install in the reverse order of removal.
9.
Fill engine coolant.
(Refer to Cooling System - "Coolant")
Note
The coolant must be injected according to the integrated thermal management module (ITM) coolant filling method.
EGR Cooler Components and Components Location
Components 1. EGR cooler2. EGR cooler pipe A3. EGR cooler pipe A gasket4. EGR cooler hose B 5. EGR cooler pipe B gasket6. EGR cooler pipe C7...
Muffler Components and Components Location
Components 1. Front muffler2. Catalytic converter & center muffler assembly3. Rear muffler 4. Gasket5. Hanger...
See also:

Engine coolant
The high-pressure cooling system has a reservoir filled with year round antifreeze coolant. The reservoir is filled at the factory. Check the antifreeze protection and coolant level at least once a ...

Starter Components
1. Front housing 2. Starter solenoid assembly 3. Lever 4. Lever packing 5. Planet shaft assembly 6. Planetary gear assembly 7. Packing 8. Shield 9. Amature assem ...

Shift Cable Removal
Removal 1. Shift the shift lever to the N range. ...

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