Kia Picanto JA Quiz
Engine Mechanical System

intercooler

In this manual: Engine Mechanical System
General Information — 8Maintenance — 30Engine Mechanical System — 46Engine Electrical System — 14Emission Control System — 11Engine Control System/Fuel System — 46Clutch System — 12Manual Transmission — 10Drive Shaft and Axle — 8Suspension System — 15Steering — 9Restraints — 17Brake System — 22Body (Interior and Exterior) — 104Body Electrical System — 80Heating, Ventilation, and Air Conditioning — 17
20steps
~120min
4/5difficulty
010203040506.95N·mlb·ft
Tightening torque found on this page
Done 0 of 20

Components and Component Location

Components

1. Intercooler Air Guard
2. Intercooler
3. Recirculation Valve (RCV) Control Solenoid Valve and Vacuum Hose
4. Recirculation Valve (RCV)
5. Recirculation Valve (RCV) Hose		 6. Intercooler Upper Mounting Bracket and Insulator
7. Intercooler Inlet Hose and Tube
8. Intercooler Outlet Hose and Tube
9. Intercooler Lower Mounting Insulator

Repair Procedures

Removal and Installation

  1. Disconnect the negative battery cable.
  2. Disconnect the outlet hose and intercooler pipe (A). Tightening torque: 4.9–6.9 N·m N·m (If equipped with a cap, tighten until the cap breaks off.)
  3. Disconnect the recirculation valve (RCV) hose (A) and the vacuum hose (B).
  4. Remove the engine cover. (Refer to Engine and Transaxle Assembly - Engine Cover)
  5. Disconnect the intercooler inlet hose (A). Tightening torque: 4.9–6.9 N·m (If equipped with a cap, tighten until the cap is removed.)
  6. Remove the front bumper assembly. (Refer to Body (Interior and Exterior) - "Front Bumper Assembly")
  7. Remove the headlamps. (Refer to Body Electrical System - "Headlamp")
  8. Disconnect the hood latch. (Refer to Body (Interior and Exterior) - Hood Latch)
  9. Remove the Universal Power Control Connector (MPCC) bracket (A).
  10. Disconnect the tank hose clamp (A).
  11. Remove the radiator upper mounting bracket (A).

    Tightening torque: 7.8–11.8 N·m

  12. Remove the radiator upper support assembly (A).

    Tightening torque: 10.8–14.7 N·m N·m

  13. Disconnect the connector (A) of the Autonomous Emergency Braking (AEB) unit and the horn connector (B).
  14. Remove the front bumper beam (A).

    Tightening torque: 16.7–26 N·m

  15. Disconnect the Boost Pressure Sensor (BPS) connector (A).
  16. Disconnect the solenoid valve connector (A).
  17. Disconnect the wiring (A) from the intercooler air guard.
  18. Remove the intercooler air guard (A).

    Tightening torque: 6.9–10.8 N·m

  19. Remove the intercooler (A).
  20. Install in the reverse order of removal.

Test yourself

A quick Kia Picanto JA quiz: every answer comes with an explanation and a link to the manual page.