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Home › Kia › 2019 › Soul ! › Repair and Diagnosis › Engine Mechanical › Intake And Exhaust System - 1.6L T › Intercooler › Repair Procedures › Removal and Installation

Removal and Installation

  1. Disconnect the battery negative terminal.
  2. Remove the air duct and air cleaner assembly.

    (refer to Intake And Exhaust System - "Air Cleaner ")

  3. Disconnect the intercooler outlet hose (A).

    Tightening torque  :

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 1: Locating Intercooler Outlet Hose
    G12238297Courtesy of KIA MOTORS AMERICA, INC.
  4. Remove the engine room under cover.

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

  5. Remove the intercooler inlet hose & pipe (A).

    Tightening torque 

    Bolts:

    19.6 - 26.4 N.m (2.0 - 2.7 kgf.m, 14.4 - 19.5 lb.ft)

    Clamp:

    4.9 - 6.8 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft)

    Fig 2: Locating Intercooler Inlet Hose & Pipe With Bolts
    G12238298Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the RCV solenoid valve hose (A) and RCV solenoid valve connector (B).
  7. Remove the wiring (C) from the intercooler.
    Fig 3: Locating RCV Solenoid Valve Hose, RCV Solenoid Valve Connector And Wiring
    G12238299Courtesy of KIA MOTORS AMERICA, INC.
  8. Disconnect the boost pressure sensor connector (A).
    Fig 4: Locating Boost Pressure Sensor Connector
    G12238300Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the front bumper.

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

  10. Remove the intercooler upper mounting bracket (A).

    Tightening torque  :

    7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb.ft)

    Fig 5: Locating Intercooler Upper Mounting Bracket
    G12238301Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the horn.

    (Refer to Body Electrical System - "HORN ")

  12. Remove the air guard (A).

    Tightening torque  :

    6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb.ft)

    Fig 6: Locating Air Guard
    G12238302Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the intercooler (A).
    Fig 7: Locating Intercooler
    G12238303Courtesy of KIA MOTORS AMERICA, INC.
  14. Install in the reverse order of removal.
    NOTE:
    • Match the marking part of hose and marking part of throttle body, compressor.
    • Match the pipe stopper and hose marking.
    • When the band part is placed on the position mark of hose, install not to exceed the mark.
    • Tighten until the torque control cap is released. If there is no torque control cap, tighten as specified torque.
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