Hyundai i-30: Intake and Exhaust System / Intercooler

Hyundai i30 (PD) 2018-2025 Service Manual / Engine Mechanical System / Intake and Exhaust System / Intercooler

Components and components location
Comoinents

1. Intercooler assembly
2. Intercooler air guard
3. Intercooler inlet hose & pipe
4. Intercooler outlet hose & pipe
 5. RCV solenoid hose B
6. RCV solenoid hose C
7. RCV hose

Repair procedures
Removal and Installation
1.
Disconnect the battery negative terminal.
2.
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
3.
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhasut System - "Air Cleaner")
4.
Remove the battery.
(Refer to Engine Electrical System - "Battery")
5.
Remove the Engine Control Module (ECM).
(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
6.
Remove the battery tray.
(Refer to Engine Electrical System - "Battery")
7.
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
8.
Remove the intercooler inlet hose and pipe.
(1)
Disconnect the intercooler inlet hose (A) from the turbocharger.

  
•
When separate the intercooler inlet pipe, pull out the quick connector clamp (A) in the direction of the arrow as shown below.
(2)
Disconnect the intercooler inlet hose (A) from the intercooler.
Tightening torque :
4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

(3)
Remove the intercooler inlet pipe (B).
Tightening torque :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)

  
•
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 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.
9.
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 B (C).
Tightening torque :
4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb-ft)

  
•
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.
10.
Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
11.
Loosen the radiator air guard mounting bolts (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)

12.
Remove the radiator lower air guard (A).
13.
Remove the intercooler assembly (A).
Tightening torque :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)

14.
Install in the reverse order of removal.

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