Hyundai i-30: Intake and Exhaust System / Intercooler
Components and components location

1. Intercooler
assembly
2. Intercooler air guard
3. Intercooler inlet hose & pipe
4. Intercooler outlet hose & pipe
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5. RCV solenoid
hose B
6. RCV solenoid hose C
7. RCV hose
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Repair procedures
1. |
Disconnect the battery negative terminal.
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2. |
Remove the engine cover.
(Refer to Engine and Transaxle Assembly - "Engine Cover")
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3. |
Remove the air duct and air cleaner assembly.
(Refer to Intake and Exhasut System - "Air Cleaner")
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4. |
Remove the battery.
(Refer to Engine Electrical System - "Battery")
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5. |
Remove the Engine Control Module (ECM).
(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
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6. |
Remove the battery tray.
(Refer to Engine Electrical System - "Battery")
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7. |
Remove the engine room under cover.
(Refer to Engine and Transaxle Assembly - "Engine Room Under Cover")
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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.

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|
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(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)
|

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(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.
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|
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9. |
Remove the intercooler outlet hose and pipe.
(1) |
Disconnect the intercooler outlet hose (A).
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(2) |
Disconnect the boost pressure sensor (BPS) connector (B).
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(3) |
Disconnect the RCV solenoid hose B (C).
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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.
|
|
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10. |
Remove the front bumper cover.
(Refer to Body - "Front Bumper Cover")
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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)
|

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12. |
Remove the radiator lower air guard (A).

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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)
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14. |
Install in the reverse order of removal.
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Components and components location
Comoinents
1. Air cleaner
upper cover
2. Air cleaner element
3. Air cleaner body
4...
Components and components location
Components
1. Intake manifold
2. Throttle body gasket
3. Throttle body
4. Vacuum pipe & hose assy
5...
Other information:
Troubleshooting
Error Item
Failure symptom
Inspection items
Detailed inspections
Relevant Parts/
Components
Screen display
TFT-LCD screen does not turn on
1)
Connector attachments
2)
Components
1)
Check the connector attachments
2)
Check B+, IGN and GND wiring
3)
Check the components
Connectors, wiring, fuses, dashboard
Warning light
Airbag warning lamp malfunction
1)
Connector attachments
2)
C-CAN
3)
Components
1)
Check airbag + signal (connectors)
2)
Check C-CAN (ACU4) signal
3)
Check the FPC attachment inside the dashboard
ACU Connectors, wiring, fuses, dashboard
Mode conversion
Integrated driving mode malfunction
1)
Connector attachments
2)
Switch
3)
Components
1)
Check the switch input (connector)
2)
Check the switch signal input
(disconnection or shorting)
3)
Check conversion with dashboard component
Switch connector, wiring dashboard
Illumination
Interior light brightness cannot be controlled...
1. Start the engine.
2. Set the mode to the desired position.
To improve the effectiveness of
heating and cooling, select:
- Heating:
- Cooling:
3. Set the temperature control to the
desired position.
4. Set the air intake control to the
outside (fresh) air position...
Categories

(1) Driver’s door power window
switch
(2) Front passenger’s door power
window switch
(3) Rear door (right) power window
switch
(4) Rear door (left) power window
switch
(5) Window opening and closing
(6) Automatic power window
(7) Power window lock switch
read more