KIA Niro: EGR Cooler Repair procedures | Intake Manifold Repair procedures

EGR Cooler Components and components location

Components

1. EGR cooler pipe A
2. EGR cooler
3. EGR cooler pipe B
4. EGR cooler coolant hose
5. Electric EGR control valve
6. EGR cooler pipe C
7. Gasket

Operation

EGR Cooler Repair procedures

Removal and
Installation

1. Disconnect the negative battery terminal.
2. Remove the engine room under cover.

    

   (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

3. Drain the coolant.

    

   (Refer to Cooling System - "Coolant")

4. Disconnect the EGR cooler coolant hose (A).

5. Disconnect the heater pump coolant hose (A).

6. Remove the exhaust manifold.

    

   (Refer to Intake and Exhaust System - "Exhaust Manifold")

7. 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)

8. Install in the reverse order of removal.
9. Fill the coolant.

    

   (Refer to Cooling System - "Coolant")

Intake Manifold Repair procedures

Intake Manifold Components And Components Location

Components

1. Intake manifold gasket
2. Intake manifold
3. Intake manifold stay
4. EGR cooler pipe C gasket
5. Electronic throttle control (ETC)
6. Electronic throttle control (ETC) gasket
7. Positive crankcase ventilation (PCV) hose

Intake Manifold Repair procedures

Removal and
Installation

Warning

• Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
• Be sure to shut off the high voltage circuit according to the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries.

1. Shut off the high voltage circuit.

   (Refer to Engine Mechanical System - "High Voltage Shut off Procedure")

2. Remove the air cleaner assembly.

    

   (Refer to Intake and Exhaust System - "Air Cleaner")

3. Remove the engine room under cover.

    

   (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

4. Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold.

5. Remove the hybrid starter generator (HSG) connector (A).

6. Separate the hybrid starter generator (HSG) coolant hose & pipe (A).

Tightening torque : 8.8 - 10.9 N*m (0.9 - 1.1 kgf*m, 6.5 - 8.0 lb*ft)

7. Disconnect the positive crankcase ventilation (PCV) hose (A).

8. Unfasten the electric throttle body control (ETC) module bolts.

    

   (Refer to Engine Control / Fuel System - "Electric Throttle Body Control System (ETC)")

9. Unfasten the EGR cooler pipe C mounting nuts (A).

Tightening torque : 7.8 - 11.8 N*m (0.8 - 1.2 kgf*m, 5.8 - 8.7 lb*ft)

10. Disconnect the hybrid starter generator (HSG) high voltage cable connector (A).

11. Remove the intake manifold stay (A).

Tightening torque : 18.6 - 23.5 N*m (1.9 - 2.4 kgf*m, 13.7 - 17.4 lb*ft)

12. Remove the intake manifold (A) with the gasket.

Tightening torque : 18.6 - 23.5 N*m (1.9 - 2.4 kgf*m, 13.7 - 17.4 lb*ft)

Warning

When installing the intake manifold, tighten the bolts and nuts, and then tighten the bolts and nuts to the specified torque in the sequence shown.

13. Install in the reverse order of removal.

Warning

When installing, replace with new gaskets.

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