Kia Picanto: Intake And Exhaust System / Intercooler

Kia Picanto JA 2017-2025 Service & Repair Manual / Engine Mechanical System / Intake And Exhaust System / Intercooler

Components and components location

Components

1. Intercooler air guard
2. Intercooler
3. Recirculation valve (RCV) control solenoid valve & vacuum hose
4. Recirculation valve (RCV)
5. Recirculation valve (RCV) hose

6. Intercooler upper mounting bracket & insulator
7. Intercooler inlet hos & pipe
8. Intercooler outlet hos & pipe
9. Intercooler lower mounting insulator

Repair procedures

Removal and Installation

1.	Disconnect the negative battery terminal.

Disconnect the intercooler outlet hose & pipe (A)

Tightening torque :

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

(If equipped with a cap, tighten it until the cap is removed.)

3.	Disconnect the recirculation valve (RCV) hose (A) and vacuum hose (B).

4.	Remove the engine room under cover. (Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")

Disconnect 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)

(If equipped with a cap, tighten it until the cap is removed.)

6.	Remover the front bumper assembly. (Refer to body (Interior and Exterior) - "Front Bumper Assembly")

7.	Remove the headlamps. (Refer to Body Electrical System - "Head Lamps")

8.	Disconnect the hood latch. (Refer to Body (Interior and Exterior) - "Hood Latch")

9.	Remove the multi-purpose check connector (MPCC) bracket (A).

10.	Disconnect the reservoir hose clip (A).

11.

Remove the radiator upper mounting bracket (A).

Tightening torque :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

12.

Remove the radiator support upper member assembly (A).

Tightening torque :

10.8 - 14.7 N·m (1.1 - 1.5 kgf·m, 8.0 - 10.8 lb·ft)

13.	Disconnect the assist emergency braking (AEB) unit connector (A) and horn connector (B).

14.

Remove the front bumper beam (A).

Tightening torque :

16.7 - 25.5 N·m (1.7 - 2.6 kgf·m, 12.3 - 18.8 lb·ft)

15.	Disconnect the boost pressure sensor (BPS) connector (A).

16.	Disconnect the solenoid valve connector (A).

17.	Remove the wiring (A) from the intercooler air guard.

18.

Remove the intercooler air guard (A).

Tightening torque :

6.9 - 10.8 N·m (0.7 - 1.1 kgf·m, 5.1 - 8.0 lb·ft)

19.	Remove the intercooler (A).

20.	Install in the reverse order of removal.

Turbo Manifold Module

Components and components location Components 1. Coupler heat protector 2. Warm-up catalytic converter (WCC) 3. Warm-up catalytic converter (WCC) gasket 4. Warm-up catalytic converter (WCC) ...

Muffler

Components and components location Components 1. Front muffler 2. Catalytic converter & Center muffler assembly 3. Rear muffler 4. Rubber hanger 5. Gasket Repair procedures ...

Other information:

Kia Picanto JA 2017-2025 Owner's Manual: Starting the engine

WARNING Always wear appropriate shoes when operating your vehicle. Unsuitable shoes (high heels, ski boots, etc.) may interfere with your ability to use the brake, accelerator pedal, and clutch (if equipped). Do not start the vehicle with the accelerator pedal depressed. T ...

Kia Picanto JA 2017-2025 Owner's Manual: Rear parking assist system precautions

The rear parking assist system may not sound consistently depending on the speed and shapes of the objects detected. The rear parking assist system may malfunction if the vehicle bumper height or sensor installation has been modified or damaged. Any non-factory installed eq ...