Kia Sorento: Exhaust Manifold Repair procedures

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

Removal and installation

To prevent scalding by the hot exhaust parts, wait until the engine cools down to room temperature.

•	Use fender covers to avoid damaging painted surfaces.

•	When handling the metal gasket, be careful not to fold or damage the surface.

•	To avoid damage, disconnect the wiring connectors carefully.

•	Replace all gaskets with new ones. Do not reuse.

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

Remove the engine wiring connectors and harness clamps around the exhaust manifold and then remove the connector brackets and wiring protector.

Tightening torque:

7.8 - 9.8 N·m (0.8 - 1.0 kgf·m , 5.8 - 7.2 lb·ft)

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

6.	Separate the oxygen sensor connector (A) from the wiring bracket.

Remove the EGR cooler pipe (A).

Tightening torque:

Bolt : 29.4 - 34.3 N·m (3.0 - 3.5 kgf·m , 21.7 - 25.3 lb·ft)

Nut : 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 / Exhaust Manifold / Repair procedures / Removal and installation illustration

Remove the exhaust manifold stay (A).

Tightening torque

Bolt B: 18.6 - 27.5 N·m (1.9 - 2.8 kgf·m , 13.7 - 20.3 lb·ft)

Bolt C: 52.0 - 57.9 N·m (5.3 - 5.9 kgf·m , 38.3 - 42.7 lb·ft)

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

Remove the exhaust manifold (A) with the gasket.

Tightening torque:

49.0 - 53.9 N·m (5.0 - 5.5 kgf·m , 36.2 - 39.8 lb·ft)

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

Do not reuse the exhaust manifold gasket.

10.

Install in the reverse order of removal

When installing the exhaust manifold, tighten the nuts with pre-torque first and then tighten the nuts with the specified torque as the sequence shown.

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

Exhaust Manifold Components and Components Location

Components 1. Exhaust manifold 2. Exhaust manifold gasket 3. Exhaust manifold stay...

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...

Kia Sorento: Exhaust Manifold Repair procedures

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