Kia Picanto: Intake And Exhaust System / Intercooler

Kia Picanto JA 2017-2023 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.
2.
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")
5.
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.
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