Hyundai Santa Cruz: Intake And Exhaust System / Intercooler

- Components

1. Intercooler outlet hose
2. Intercooler upper mounting bracket
3. Intercooler upper mounting insulator
4. Intercooler
5. Intercooler air guard
6. Intercooler lower mounting insulator
7. Intercooler inlet hose and pipe
8. Recirculation valve (RCV) hose
9. Recirculation valve (RCV) & purge pipe
10. Purge pipe gasket

1.Disconnect the battery negative terminal.

2.Remove the air cleaner assembly.(Refer to Intake and Exhasut System - "Air Cleaner")

3.Remove the front bumper beam assembly.(Refer to Body (Interior and Exterior) - "Front Bumper Beam Assembly")

4.Remove the air intake shield (A).

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

5.Remove the intercooler air guard (A).

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

6.Disconnect the intercooler inlet hose (A).

1)When disconnect the intercooler inlet hose, pull out the quick connector clamp (A) in the direction of the arrow as shown below.

2)Move the quick connector clamp from position (B) to position (C) as shown below and pull out the quick connector hose.

7.Disconnect the intercooler outlet hose (A).

1)When disconnect the intercooler inlet hose, pull out the quick connector clamp (A) in the direction of the arrow as shown below.

2)Move the quick connector clamp from position (B) to position (C) as shown below and pull out the quick connector hose.

8.Disconnect the positive crankcase ventilation (PCV) hose (A).

9.Disconnect the recirculation valve (RCV) hose (A).

10.Loosen 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)

11.Remove the intercooler assembly (A).

12.Remove the recirculation valve (RCV) (A) & purge pipe (B) from the intercooler.

Tightening torque :Recirculation valve (RCV) bolts : 7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft) Purge pipe bolts : 18.6 - 27.4 N.m (1.9 - 2.8 kgf.m, 13.7 - 20.3 lb-ft)

13.Install in the reverse order of removal.