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Home › Kia › 2021 › K5 EX › Repair and Diagnosis › Engine Mechanical › Intake And Exhaust System - 1.6L › Intercooler › Repair Procedures › Removal And Installation

Removal And Installation

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

    (Refer to " Removal and Installation  ") 

  3. Remove the engine room under cover.

    (Refer to " Removal And Installation  ") 

  4. Disconnect the intercooler inlet hose (A).

    Tightening torque:

    4.9 - 6.7 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.0 lb.ft, 43.4 - 60.8 lb.in)

    G13833562Courtesy of KIA MOTORS AMERICA, INC.
  5. Disconnect the intercooler outlet hose (A).
    G13833563Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    1. To remove the intercooler tube, pull out the quick connect clip (A) in the direction of the arrow shown in the image below.
      G13833564Courtesy of KIA MOTORS AMERICA, INC.
    2. As shown in the figure below, move the quick connect clamp B to C, and then pull out the quick connect tube.
    G13833565Courtesy of KIA MOTORS AMERICA, INC.
    G13833566Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the front bumper assembly.

    (Refer to " Replacement  ") 

  7. Disconnect the intake air temperature sensor connector (A).
    G13833567Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove the intercooler air guide (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 -1.2 kgf.m, 7.2 - 8.7 lb.ft)

    G13833568Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the intercooler upper mounting bracket bolt (A).

    Tightening torque: 

    9.8 - 11.8 N.m (1.0 -1.2 kgf.m, 7.2 - 8.7 lb.ft)

    G13833569Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the intercooler upper mounting bracket (A) from the intercooler.
    G13833570Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the intercooler (A).
    G13833571Courtesy of KIA MOTORS AMERICA, INC.
  12. Install in the reverse order of removal.
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