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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:

Front Strut Assembly: Components and Components Location
Components 1. Strut assembly2. Insulator3. Bearing4. Spring upper pad5. Spring6. Dust cover7. Spring lower pad ...

Do not lie down
To reduce the chance of injuries in the event of an accident and to achieve maximum effectiveness of the restraint system, all passengers should be sitting up and the front and rear seats should b ...

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