Hyundai i20 Quiz
Engine Mechanical System

Intercooler Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 79Engine Electrical System — 50Emission Control System — 22Engine/Fuel Control System — 107Clutch System — 27MANUAL TRANSMISSION SYSTEM — 21Drive Shaft and Axle — 18Suspension System — 29Steering System — 21Restraint — 41Braking System — 53Body Work (Interior and Exterior) — 190Body Electrical System — 181Heating, Ventilation and Air Conditioning — 58
13steps
~78min
3/5difficulty
010203040506.95N·mlb·ft
Tightening torque found on this page
Done 0 of 13

DEPOSIT

  1. Disconnect the negative battery cable.
  2. Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")
  3. Remove the engine undercover. (Refer to Engine and Transaxle Assembly - "Engine Undercover")
  4. Remove the front bumper. (Refer to Body - "Front Bumper Cover")
  5. Disconnect the boost pressure sensor (BPS) connector (A).
  6. Remove the intercooler inlet hose (A). Tightening torque: Hose clamp bolt: 4.9~6.9 N·m (If equipped with a cap, tighten until the cap is removed.)
  7. Disconnect the intercooler outlet hose (A) and the RCV solenoid valve (B). Tightening torque: 4.9~6.9 N·m (If equipped with a cap, tighten until the cap is removed.)
  8. Disconnect the solenoid valve connector (A), then disconnect the wiring (B) from the intercooler.
  9. Remove the air intake cover. (Refer to Intake and Exhaust System - Air Cleaner)
  10. Loosen the upper intercooler mounting bracket bolt (A) and remove the mounting bracket (B).

    Tightening torque: 9.8–11.8 N·m

  11. Remove the intercooler air guide (A).

    Tightening torque: 6.9 ~ 10.8 N·m

  12. Remove the intercooler (A).
  13. To install, perform the removal procedure in reverse order.

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