Hyundai Kona: Intake and Exhaust System / Intercooler Repair procedures

Hyundai Kona (OS) 2018-2021 Service Manual / Engine Mechanical System / Intake and Exhaust System / Intercooler Repair procedures

Removal and Installation

1.	Disconnect the battery negative terminal.

2.	Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")

3.	Remove the engine room under cover. (Refer to Engine And Transmission Assembly - "Engine Room Under Cover")

4.	Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")

Remove the intercooler inlet hose and pipe.

(1)

Remove the intercooler inlet hose (A).

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.

•	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 turbocharger and remove the intercooler inlet pipe (B).

Tightening torque

Clamp :

4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

Mounting bolt :

18.6 - 23.5 N.m (1.9 - 2.4kgf.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 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.

Remove the intercooler outlet hose and pipe.

(1)	Disconnect the intercooler outlet hose (A).

(2)	Disconnect the boost pressure sensor (BPS) connector (B).

(3)	Disconnect the RCV solenoid hose (C).

(4)	Disconnect the RCV solenoid connector (D).

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 marking of hose must be in line with the stopper of the throttle body.

•	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.

7.	Remove the front bumper. (Refer to Body (Interior and Exterior) - "Front Bumper")

Remove the inter cooler air guard (A).

Tightening torque :

6.8 - 10.7 N.m (0.7 - 1.1 kgf.m, 5.0 - 7.9 lb-ft)

Remove the front bumper beam (A).

Tightening torque :

30.4 - 46.1 N.m (3.1 - 4.7 kgf.m, 22.4 - 34.0 lb-ft)

10.

Remove the inter cooler mounting bolts (A).

Tightening torque :

6.8 - 10.7 N.m (0.7 - 1.1 kgf.m, 5.0 - 7.9 lb-ft)

[LH]

[RH]

11.	Remove the inter cooler assembly (A).

12.	Install in the reverse order of removal.

Intercooler Components and components location

Components 1. Intercooler 2. Intercooler air guard 3. Intercooler inlet hose 4. Intercooler inlet pipe 5. Intercooler outlet hose 6. Intercooler outlet ...

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