Hyundai Kona Quiz
Engine Mechanical System

Intercooler Repair Procedures

In this manual: Engine Mechanical System
General Information — 17Engine Mechanical System — 85Engine Electrical System — 50Emission Control System — 26Engine Control System/Fuel System — 152DCT (Dual Clutch Transmission) System — 50Four-Wheel Drive (4WD) System — 21Propeller Shaft and Axle (2WD-FF) — 28Suspension System (without ECS) — 32Steering — 21Restraints — 38Brake System — 64Body (Interior and Exterior) — 205Body Electrical System — 1Heating, Ventilation, and Air Conditioning — 66
12steps
~72min
3/5difficulty
010203040506.95N·mlb·ft
Tightening torque found on this page
Done 0 of 12

Removal and Installation

  1. Disconnect the negative battery cable.
  2. Remove the engine cover. (Refer to Engine and Transaxle Assembly - "Engine Cover")
  3. Remove the engine compartment cover. (Refer to Engine and Transaxle Assembly - "Engine Compartment Under Cover")
  4. Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")
  5. Remove the intake hose and intercooler tube.
    1. Remove the intercooler inlet hose (A).

      Tightening torque: 4.9–6.9 N·m

    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 Mounting bolt: 18.6–24 N·m
  6. Remove the intercooler outlet hose and tube.
    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 valve connector (D).

    Tightening torque: 4.9–6.9 N·m

  7. Remove the front bumper. (Refer to Body (Interior and Exterior) - "Front Bumper")
  8. Remove the intercooler air guard (A).

    Tightening torque: 6.8–10.7 N·m

  9. Remove the front bumper beam (A).

    Tightening torque: 30.4–46 N·m

  10. Remove the intercooler mounting bolts (A).

    Tightening torque: 6.8–10.7 N·m

    [LH]
    [RH]
  11. Remove the intercooler assembly (A).
  12. Install in the reverse order of removal.

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