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Kia Sportage: Intercooler: Repair procedures - Intake And Exhaust System - Engine Mechanical System - Kia Sportage SL Service & Repair ManualKia Sportage: Intercooler: Repair procedures

Third generation SL (2010–2016) / Kia Sportage SL Service & Repair Manual / Engine Mechanical System / Intake And Exhaust System / Intercooler: 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 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

3.
Disconnect the recirculation valve connector (A) and the vacuum hose (B), and then remove the intercooner inlet pipe & hose 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.
Intercooler: Components and Components Location
Components 1. Recirculation hose2. Intercooler inlet hose & pipe assembly3. Intercooler outlet hose & pipe assembly4. Intercooler mounting bracket5. Intercooler upper mounting insulator6. ...

Muffler: Components and Components Location
Components 1. Front muffler2. Catalytic converter3. Center muffler4. Main muffler5. Gasket ...

Other Information:

Valve Body: Repair procedures
Removal 1. Remove the under cover (A). Tightening torque : 19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~ 18.1 lb-ft) 2. Remove the drain plug (A) and drain the ATF totally and then reinstall ...

Operating precautions for catalytic converters
WARNING - Fire Do not park, idle or drive the vehicle over or near flammable objects, such as grass, vegetation, paper, leaves, etc. A hot exhaust system can ignite flammable items under ...

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