Kia Sportage 2005-06

Exhaust Manifold

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Removal & Installation



2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the under cover.
  4.  
  5. Remove the front exhaust pipe.
  6.  
  7. Disconnect the oxygen sensor connector.
  8.  
  9. Remove the cooling fan motor assembly.  
  10.  
  11. Disconnect the negative cable from the battery.
  12.  
  13. Recover the refrigerant with a recovery/charging station.
  14.  
  15. Loosen the drive belt.
  16.  
  17. Remove the bolts. Then, disconnect the suction line (A) and discharge line (B) from the compressor. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
  18.  
  19. Disconnect the compressor clutch connector (A), then remove the mounting bolts and the compressor (B).
  20.  
  21. Remove the left heat protector.
  22.  
  23. Remove the left exhaust manifold and gasket.
  24.  
  25. Remove the alternator.  
  26.  
  27. Remove the right halfshaft.  
  28.  
  29. Remove the right heat protector.
  30.  
  31. Remove the right exhaust manifold and gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold - 2.7L engine

  32.  

To install:

Click image to see an enlarged view

Fig. Compressor bolt identification - 2.7L engine. A, B and C: 118mm (4.65 in.); D: 94mm (3.70 in.)

  1. Install the right exhaust manifold and gasket. Tighten to 30-35 Nm (22-26 ft. lbs.).
  2.  
  3. Install the right heat protector. Tighten to 17-22 Nm (12-16 ft. lbs.).
  4.  
  5. Install the right halfshaft.
  6.  
  7. Install the alternator. 
  8.  
  9. Install the exhaust manifold and gasket. Tighten to 30-35 Nm (22-26 ft. lbs.).
  10.  
  11. Install the left heat protector. Tighten to 12-15 Nm (9-11 ft. lbs.).
  12.  
  13. Install the air conditioner compressor.  
  14.  
  15. Install the cooling fan motor assembly. 
  16.  
  17. Connect the oxygen sensor connector.
  18.  
  19. Install the front exhaust pipe. Tighten to 30-40 Nm (22-30 ft. lbs.).
  20.  
  21. Install the under cover.
  22.  

2.0L Engine


Click image to see an enlarged view

Fig. Exhaust manifold and related parts - 2.0L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the front oxygen sensor connector.
  6.  
  7. Remove the front muffler.
  8.  
  9. Remove the heat protector.
  10.  
  11. Remove the exhaust manifold and catalytic converter assembly.
  12.  
  13. Installation is in the reverse order of removal. Observe the following torques:

    Front muffler: Nut: 39-59 Nm (29-43 ft. lbs.); Bolt: 29-39 Nm (22-29 ft. lbs.)
     
    Heat protector: 17-22 Nm (12-16 ft. lbs.)
     
    Exhaust manifold/catalytic converter assembly: 42-54 Nm (31-40 ft. lbs.)
     

  14.  

 
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