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Home >> Kia >> 2021 >> Seltos S, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 6 (Intake And Exhaust System - 1.6L) >> Intercooler >> Repair Procedures >> Removal And Installation

Removal And Installation

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the battery negative terminal.
  2. Remove the engine cover.

    (Refer to Engine and Transaxle Assembly - "ENGINE COVER ")

  3. Remove the engine room under cover.

    (Refer to Engine And Transaxle Assembly - "ENGINE ROOM UNDER COVER ")

  4. Remove the air duct and air cleaner assembly.

    (Refer to Intake and Exhaust System - "AIR CLEANER ")

  5. Remove the intercooler inlet hose and pipe.
    1. Remove the intercooler inlet hose (A).

      Tightening torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft, 43.3 - 60.7 lb.in)

      G13480335Courtesy of KIA MOTORS AMERICA, INC.
      NOTE:
      • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
      • The groove of hose must be in line with the protrusion of the pipe.
      • The band must be located on the position mark of hose and must not run over it.
      • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
    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 (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft, 43.3 - 60.7 lb.in)

      Mounting bolt:

      18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb.ft)

    G13480336Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
    • The groove of hose must be in line with the protrusion of the pipe or turbocharger.
    • The band must be located on the position mark of hose and must not run over it.
    • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  6. Remove the intercooler outlet hose and pipe.
    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 connector (D).

      Tightening torque: 

      4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb.ft, 43.3 - 60.7 lb.in)

    G13480337Courtesy of KIA MOTORS AMERICA, INC.
    G13480338Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
    • The marking of hose must be in line with the stopper of the throttle body.
    • The band must be located on the position mark of hose and must not run over it.
    • Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
  7. Remove the front bumper assembly.

    (Refer to Body (Interior and Exterior) - "FRONT BUMPER ASSEMBLY ")

  8. Remove the intercooler air guard (A).

    Tightening torque: 

    6.8 - 10.7 N.m (0.7 - 1.1 kgf.m, 5.0 - 7.9 lb.ft, 60.7 - 95.4 lb.in)

    G13480339Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the front bumper beam (A).

    Tightening torque: 

    30.4 - 46.1 N.m (3.1 - 4.7 kgf.m, 22.4 - 34.0 lb.ft)

    G13480340Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the intercooler (A).

    Tightening torque: 

    6.8 - 10.7 N.m (0.7 - 1.1 kgf.m, 5.0 - 7.9 lb.ft, 60.7 - 95.4 lb.in)

    G13480341Courtesy of KIA MOTORS AMERICA, INC.
  11. Install in the reverse order of removal.
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