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Home >> Genesis >> 2021 >> G80 3.5T, RWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Intake And Exhaust System - 3.5L >> Water Cooled Intercooler >> Repair Procedures >> Removal and Installation

Removal and Installation

  1. Disconnect the battery negative terminal from the trunk room.
  2. Remove the engine cover. (Refer to Engine and Transmission Assembly - "ENGINE COVER ")
  3. Remove the engine room under cover. (Refer to Engine and Transmission Assembly - "ENGINE ROOM UNDER COVER ")
  4. Remove the LH and RH air cleaner assembly. (Refer to Intake and Exhaust System - "AIR CLEANER ")
  5. Disconnect the water cooled intercooler outlet hose and then drain the water cooled intercooler coolant. (Refer to Cooling System - "COOLANT ")
  6. Disconnect the water cooled intercooler inlet hose (A).
    G15555940Courtesy of HYUNDAI MOTOR AMERICA
  7. Remove the water cooled intercooler coolant reservoir tank and bracket. (Refer to Cooling System - "RESERVOIR TANK ")
  8. Disconnect the electric water pump (EWP) hose (A).
    G15555941Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the ATF warmer, if necessary.
  10. Remove the electric water pump (EWP) and bracket. (Refer to Cooling System - "ELECTRIC WATER PUMP (EWP) ")
  11. Remove the water cooled intercooler mounting bracket (A).

    Tightening torque: 

    Bolt: 21.6 - 32.4 N.m (2.2 - 3.3 kgf.m, 15.9 - 23.9 lb.ft)

    Nut: 49.0 - 53.9 N.m (5.0 - 5.5 kgf.m, 36.2 - 39.8 lb.ft)

    G15555942Courtesy of HYUNDAI MOTOR AMERICA
  12. Remove the water cooled intercooler LH inlet pipe (A).
    G15555943Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • When separate the intercooler inlet pipe, pull out the quick connector clamp (A) in the direction of the arrow as shown below.
    G15555944Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the water cooled intercooler RH inlet pipe (A).
    G15555945Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • When separate the intercooler inlet pipe, pull out the quick connector clamp (A) in the direction of the arrow as shown below.
    G15555946Courtesy of HYUNDAI MOTOR AMERICA
  14. Separate the intercooler outlet hose quick clamp (A).
    G15555947Courtesy of HYUNDAI MOTOR AMERICA

    Information 

    • When separate the intercooler outlet hose, pull out the quick connector clamp (A) in the direction of the arrow as shown below.
    G15555948Courtesy of HYUNDAI MOTOR AMERICA
  15. Disconnect the dual purge hose (A).
    G15555949Courtesy of HYUNDAI MOTOR AMERICA
  16. Remove the sensor bracket (A).
    G15555950Courtesy of HYUNDAI MOTOR AMERICA
  17. Remove the water cooled intercooler (A) with the intercooler outlet hose.
    G15555951Courtesy of HYUNDAI MOTOR AMERICA
  18. Install in the reverse order of removal.
  19. Fill the water cooled intercooler coolant. (Refer to Cooling System - "COOLANT ")
    NOTE:
    • The water cooled intercooler coolant must be injected according to the electric water pump (EWP) coolant filling method.
  20. Recheck coolant level.
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