Kia Sportage: Intercooler

Components and Components Location

 Components

1. Recirculation hose
2. Intercooler inlet hose & pipe assembly
3. Intercooler outlet hose & pipe assembly
4. Intercooler mounting bracket
5. Intercooler upper mounting insulator
6. Intercooler
7. Intercooler lower mounting insulator

Repair procedures

Removal and Installation

1. Disconnect the battery negative terminal (A).

Tightening torque 4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)

2. Remove the air cleaner assembly.

1. Remove the air duct (A).
2. Disconnect the breather hose (B), the recirculation hose (C) and the brake booster vacuum hose (D).
3. Disconnect the air intake hose (E) and then remove the air cleaner assembly (F).

Tightening torque

Hose clamp bolt: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

Air cleaner assembly bolts: 7.8 ~ 9.8N.m (0.8 ~ l.0kgf.m, 5.8 ~ 7.2lb-ft)

3. Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooler inlet pipe assembly (C).

4. Disconnect the boost pressure sensor connector (A) and then remove the intercooler outlet pipe & hose assembly (B).

Tightening torque 4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m 3.6 ~ 5.1 lb-ft)

5. Remove the under cover (A).

Tightening torque: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

6. Remove the front bumper. (Refer to BD group)

7. Remove the front bumper upper stiffner (A).

8. Remove the radiator upper cover (A).

9. Remove the intercooler upper mounting bracket (A) and then remove the intercooler (B).

Tightening torque 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

10. Installation is reverse order of removal.

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