Removal and Installation

Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "ENGINE COVER ")
Remove the air duct.
(Refer to Intake and Exhaust System - "Air Cleaner ")
Remove the battery
(Refer to Engine Electrical System - "BATTERY ")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner ")
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "ENGINE ROOM UNDER COVER ")
Disconnect the recirculation valve connector (A) and the vacuum hose (B).

Fig 1: Disconnecting Recirculation Valve Connector And Vacuum Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intercooler inlet pipe & hose assembly (A).
Tightening torque

Hose clamp bolt:

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.)

Pipe mounting Bolt:

14.7 - 19.5 N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb.ft)

Fig 2: Removing Intercooler Inlet Pipe & Hose Assembly
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
Disconnect the boost pressure sensor connector (A).

Fig 3: Disconnecting Boost Pressure Sensor Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intercooler outlet pipe & hose assembly (B).
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.)

Fig 4: Removing Intercooler Outlet Pipe & Hose Assembly
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Align the marks of the intercooler pipes/hoses and assembling parts.
Remove the front bumper cover.
(Refer to Body - "FRONT BUMPER COVER ")
Disconnect the wiring clips (A).

Fig 5: Disconnecting Wiring Clips
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intercooler upper bracket (A).
Tightening torque:

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.7 - 8.7 lb.ft)

Fig 6: Removing Intercooler Upper Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Remove the dual air duct (A).
Tightening torque:

7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.7 - 8.7 lb.ft)

Fig 7: Removing Dual Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove intercooler assembly (A) from the vehicle.

Fig 8: Removing Intercooler Assembly From Vehicle
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.