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Repair procedures: Replacement

  1. Disconnect the negative (-) battery terminal.
  2. Recover the refrigerant with a recovery/recycling/charging station.
  3. When the engine is cool, drain the engine coolant from the radiator.
  4. Remove the expansion valve cover (A).
    Fig 1: Expansion Valve Cover
    G07369606Courtesy of KIA MOTORS AMERICA, INC.
  5. Remove the bolts (A) and the expansion valve (B) from the evaporator core.

    Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

    Fig 2: Expansion Valve & Bolts
    G07369607Courtesy of KIA MOTORS AMERICA, INC.
  6. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.
    Fig 3: Inlet & Outlet Heater Hoses
    G07369608Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION:
    • Engine coolant will spill when the hoses are disconnected; drain it into a clean drip pan. Be sure not to let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.
  7. Remove the crash pad.

    For coupe, refer to CRASH PAD . For sedan, refer to CRASH PAD .

  8. Remove the cowl cross bar assembly.

    For coupe, refer to COWL CROSS BAR . For sedan, refer to COWL CROSS BAR .

  9. Remove the heater & blower unit (A) after loosening mounting bolts.
    Fig 4: Heater & Blower Unit Mounting Bolts
    G07369609Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the blower unit (A) from heater unit (B) after loosening 3 screws.
    Fig 5: Blower Unit
    G07369610Courtesy of KIA MOTORS AMERICA, INC.
    Fig 6: Heater Unit
    G07369611Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove the cover (A).
    Fig 7: Heater Core Cover
    G07369612Courtesy of KIA MOTORS AMERICA, INC.
  12. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core (A).
    Fig 8: Heater Core
    G07369613Courtesy of KIA MOTORS AMERICA, INC.
  13. Remove the heater unit lower case (A).
    Fig 9: Heater Unit Lower Case
    G07369614Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the evaporator core (A).
    Fig 10: Evaporator Core
    G07369615Courtesy of KIA MOTORS AMERICA, INC.
  15. Be careful that the inlet and outlet pipe are not bent during evaporator core removal, and pull out the heater core.
  16. Install the heater core in the reverse order of removal.
  17. Installation is the reverse order of removal, and note these items :
    1. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
    2. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing. Be sure to use the right O-rings for R-134a to avoid leakage.
    3. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
    4. Do not spill the refrigerant oil on the vehicle; it may damage paint; if the refrigerant oil contacts the paint, wash off immediately.
    5. Apply sealant to the grommets.
    6. Make sure that there is no air leakage.
    7. Charge the system and test its performance.
    8. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
    9. Refill the cooling system with engine coolant.
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