Kia Picanto JA Quiz
Engine Mechanical System

Turbo Manifold Module

In this manual: Engine Mechanical System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
31steps
~186min
4/5difficulty
0102030405011.89N·mlb·ft
Tightening torque found on this page
Done 0 of 31

Components and Component Location

Components

1. Coupling Heat Shield
2. Warm-Up Catalytic Converter (WCC)
3. Warm-Up Catalytic Converter (WCC) Gasket
4. Warm-Up Catalytic Converter (WCC) Upper Support
5. Exhaust Manifold Upper Support
6. Turbocharger Manifold
7. Turbocharger Manifold Gasket

8. Exhaust Manifold Heat Shield
9. Oil Drain Tube and Hose
10. Oil Drain Tube A Gasket
11. Oil Drain Tube B Gasket
12. Oil Supply Tube and Hose
13. Water Supply Tube and Hose
14. Water Drain Pipe and 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 cover. (Refer to Engine and Transaxle Assembly - Engine Cover)
  2. Drain the engine coolant. (Refer to Cooling System - "Engine Coolant")
  3. Remove the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
  4. Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")
  5. Disconnect the extension connector (A) of the Electric Wastegate Actuator (EWGA).
  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 turbocharger drain pipe hose (A).
  9. Remove the heat shield of the coupling (A) and the water drain pipe (B). Tightening Torque Heat Shield Mounting Bolt: 9.8–11.8 N·m (If equipped with a cap, tighten until the cap is removed.) Eye Bolt: 26.4–32 N·m Pipe Mounting Bolt: 9.8–11.8 N·m
  10. Remove the exhaust manifold support (A).

    Torque: 39.2 – 44 N·m

  11. Remove the warm-up catalytic converter (WCC) upper support (A), then remove the warm-up catalytic converter (WCC) (B). Tightening Torque Warm-Up Catalytic Converter (WCC): 49.0–54 N·m WCC Upper Support: 18.6–24 N·m
  12. Remove the water supply hose and pipe (A) and the oil drain pipe (B). Tightening torque: Water supply pipe: 26.4–32 N·m Oil drain pipe: 9.8–11.8 N·m
  13. Remove the oil supply pipe (A).

    Tightening torque: 11.8–17.7 N·m

  14. Remove the exhaust manifold heat shield (A).

    Tightening Torque: 9.8–11.8 N·m

  15. Remove the turbocharger manifold module (A) with the gasket.

    Tightening torque: 35.3–41 N·m

  16. Install in the reverse order of removal.

Inspection on Vehicle

Turbocharger Diagnostic Flow

If any problem related to the turbocharger occurs, such as lack of engine power, poor acceleration, abnormal engine noise, or oil leakage, inspect the turbocharger according to the following procedure.
  1. Inspect the turbocharger assembly and exhaust outlet (or downpipe).
    • Check that the gasket is installed.
    • Make sure the mounting bolts (or nuts) are tightened properly.
    • Check for gas leakage.
    • Check the parts for damage, such as cracks.
    Exhaust gas leakage due to a missing gasket or insufficiently tightened mounting bolts (or nuts) may cause abnormal engine noise. If the cause is found, tighten the mounting bolts (or nuts) to the specified torque, or replace the gasket or damaged parts with new ones as necessary.
  2. Check the exhaust manifold and cylinder head assembly.
    • Check that the gasket is installed.
    • Make sure the mounting bolts (or nuts) are tightened properly.
    • Check for gas leakage.
    Exhaust gas leakage due to a missing gasket or insufficiently tightened mounting bolts (or nuts) may cause abnormal engine noise. If the cause is found, tighten the mounting bolts (or nuts) to the specified torque, or install a new gasket as necessary.
  3. Check the turbocharger oil supply pipe and hose, and the oil drain pipe and hose.
    • Check that the gasket is installed.
    • Check that the mounting bolts are tightened correctly.
    • Check that the clamps are in place.
    • Check the oil pipes and hoses for damage (kinks, crushing, tears, or cracks).
    If exhaust gas leaks because a gasket was not installed or mounting bolts are insufficiently tightened, oil leakage may occur. If the oil supply pipe and hose are damaged, insufficient engine oil will be supplied to the turbocharger, which may cause turbocharger damage. If the oil drain pipe and hose are damaged or clogged, engine oil will not drain smoothly, which may cause oil leakage from the turbocharger. If the cause is found, tighten the mounting bolts (or nuts) to the specified torque, or replace the gasket or damaged parts with new ones as necessary.
  4. Check for oil leakage between the center housing and the compressor housing.
    • Make sure the mounting bolts are tightened properly.
    • Check for oil leakage.
    A damaged O-ring (gasket) between the center housing and the compressor housing may cause oil leakage. If oil leakage is found, replace the turbocharger with a new one.
  5. Check the turbocharger actuator.
    • Electronic actuator: check the actuator rod movement when the forced operation of the electric actuator is performed by the ECM. (Refer to the Diagnostic Trouble Code manual.)
    A damaged turbocharger actuator may cause insufficient 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 that the compressor wheel is not damaged (bent or deformed).
    • Make sure the compressor wheel rotates smoothly. For example
    A damaged compressor wheel may cause abnormal turbocharger noise and poor acceleration. If the compressor wheel is damaged or deformed, replace the turbocharger with a new one.
  7. Check the turbocharger turbine wheel.
    • Check that the turbine wheel is not damaged.
    • Make sure the turbine wheel rotates smoothly. For example
    A damaged turbine wheel may cause abnormal turbocharger noise and poor acceleration. If the turbine wheel is damaged or deformed, replace the turbocharger with a new one.
  8. Check the breather hose. (Refer to Group FL)
    • Check that the breather hose is not damaged (kinked or clogged).
    • Check whether the positive crankcase ventilation (PCV) valve is clogged.
    If the breather hose is bent or clogged, internal pressure will increase and engine oil will not flow smoothly into the turbocharger, causing turbocharger damage and oil leakage. If the cause is found, replace the breather hose or related parts with new ones.
  9. Check the intake hose connected to the turbocharger.
    • Check the intake hose for damage (kinks, crushing, disconnection, or tears).
    If the cross-section of the intake hose decreases due to bending or crushing, the intake air supplied to the turbocharger will be reduced and the pressure before the turbocharger will drop, causing turbocharger damage or oil leakage. If the intake hose is disconnected or torn, foreign material may enter the turbocharger and damage it. If the intake hose is damaged, replace it with a new one.
  10. Check the air cleaner.
    • Check the air cleaner filter for contamination.
    • Check the air cleaner filter for water intrusion.
    • Check the air cleaner cover for contamination.
    • Make sure the air cleaner filter is a genuine part.
    If the air cleaner filter is excessively wet or dirty, or a non-genuine part is used, the air supply to the turbocharger will be reduced and the pressure before the turbocharger will drop, causing turbocharger damage and oil leakage. If the air cleaner filter is excessively wet or dirty, replace it with a new one.
  11. Check the intercooler hoses and pipes.
    • Make sure the intercooler hoses and pipes are connected correctly.
    • Check the intercooler hoses and pipes for damage (kinks, disconnection, or tears).
    • Check the intercooler hoses and pipes for damage such as cracks.
    • Make sure the clamps are in their proper positions.
    If the intercooler hoses and pipes are damaged or disconnected, oil may leak from the hoses and pipes, and the turbocharger may exceed the permissible speed, which may cause turbocharger damage. If the intercooler hoses and pipes are damaged, replace them with new ones.
  12. Inspect the intercooler.
    • Check the intercooler pipes and tanks for damage (oil leakage or cracks).
    If the intercooler is damaged, the turbocharger may exceed the permissible speed, causing turbocharger damage. If the intercooler is damaged, replace it with a new one.
  13. Check the engine oil.
    • Check the engine oil level.
    • Check the engine oil for discoloration, water contamination, and loss of viscosity.
    • Check the engine oil grade.
    If the engine oil level is low, the amount of engine oil supplied to the turbocharger will decrease, causing the turbocharger bearings to seize due to insufficient lubrication and cooling. If the cause is found, add or replace the engine oil.
  14. Check the engine oil pressure.
    • Engine oil pressure: check the oil pressure with an oil pressure gauge after removing the oil pressure sensor from the cylinder block.
    • Check the engine oil screen in the oil pan if the engine oil level is low. Then check the nozzles for gas leakage if foreign material has accumulated on the oil screen.
    If the engine oil level is low, the amount of engine oil supplied to the turbocharger will decrease, causing the turbocharger bearings to seize due to insufficient lubrication and cooling. If the cause is found, add or replace the engine oil. If foreign material has accumulated on the oil screen, clean the oil screen and replace the nozzle washer with a new one after checking the nozzles for gas leakage. Inspect engine parts related to oil, such as the oil pump, if necessary.
  15. Check the injectors, sensors, etc. (Refer to Group FL).
    • Check that the injectors operate correctly.
    • Check that sensors such as the Mass Air Flow Sensor (MAFS), Intake Air Temperature Sensor (IATS) and Boost Pressure Sensor (BPS) operate correctly.
    Malfunction of the injectors, sensors, EGR valve, etc. may cause a decrease in engine power. If the cause of the problem is found, replace the related parts with new ones.
If no problem is found with the turbocharger, inspect the components related to the turbocharger according to the procedure described below.

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