Hyundai i-30: Intake and Exhaust System / Turbo Charger & Exhaust Manifold

Hyundai i30 (PD) 2018-2024 Service Manual / Engine Mechanical System / Intake and Exhaust System / Turbo Charger & Exhaust Manifold

Components and components location
Components

1. Catalytic converter (WCC)
2. Turbo manifold module
3. Catalytic converter (WCC) heat protector
4. Turbo charger gasket
5. Catalytic converter (WCC) gasket
6. V - clamp
7. Oxygen sensor
8. Catalytic converter (WCC) upper stay
9. Catalytic converter (WCC) stay
10. Turbo charger oil feed pipe gasket
11. Turbo charger oil feed pipe
12. Turbo charger water feed pipe
13. Turbo charger oil drain pipe
14. Turbo charger oil drain B gasket
15. Turbo charger oil drain A gasket
16. Turbo charger water drain pipe

Repair procedures
Removal and Installation
1.
Disconnect the battery negative teminal.
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 intercooler inlet hose and pipe.
(1)
Disconnect the intercooler inlet hose (A) from the turbocharger.
Tightening torque :
4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

  
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The groove of hose must be in line with the protrusion of the pipe or turbocharger.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
(2)
Disconnect the intercooler inlet hose (A) from the intercooler.
Tightening torque :
4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

(3)
Remove the intercooler inlet pipe (B).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

  
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The marking of hose must be in line with the stopper of the pipe.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
5.
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the exhaust manifold.

6.
Remove the oxygen sensor (A).
Tightening torque :
39.2 - 49.1 N.m (4.0 - 5.0 kgf.m, 28.9 - 36.2 lb-ft)

7.
Remove the heat protector (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

8.
Remove the turbocharger water drain pipe (A) and the wiring connector bracket (B).
Tightening torque
bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
eye bolt : 26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)

9.
Remove the catalytic converter (WCC) bracket (A) and EGR pipe A (B).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

10.
Remove the catalytic converter (WCC) stay (A).
Tightening torque :
39.2 - 44.1 N.m (4.0 - 4.5 kgf.m, 28.9 - 32.5 lb-ft)

11.
Remove the V-clamp (A) and then remove the catalytic converter (WCC) (B) with the gasket.
Tightening torque :
13.5 - 16.4 N.m (1.38 - 1.68 kgf.m, 9.9 - 12.1 lb-ft)

  
When installing, replace with a new gasket.
12.
Remove the turbo charger oil feed pipe (A).
Tightening torque
Eye bolt [To turbo] : 22.5 - 26.4 N.m (2.3 - 2.7 kgf.m, 16.6 - 19.5 lb-ft)
Bolt [To block] : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

  
When installing, replace with a new gasket.
13.
Remove the turbo charger water feed pipe (A).
Tightening torque
Bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
Eye bolt : 26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)

  
When installing, replace with a new gasket.
14.
Remove the turbo charger lower heat protector (A).
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)

15.
Remove the turbo charger oil drain pipe (A).
Tightening torque :
Bolt (To block) : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
Eye bolt (To turbo) : 22.5 - 26.4 N.m (2.3 - 2.7 kgf.m, 16.6 - 19.5 lb-ft)

  
When installing, replace with a new gasket.
16.
Discoccect the EGR cooler hose (A).

17.
Remove the turbo manifold module (A) with the gasket.
Tightening torque :
34.3 - 42.2 N.m (3.5 - 4.3 kgf.m, 25.3 - 31.1 lb-ft)

  
When installing, replace with new gaskets.
When installing the exhaust manifold, tighten the nuts with pre-torque first, and then tighten the nuts with pecified torque in the sequence shown.

18.
Install in the reverse order of removal.

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