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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2011 Hyundai Elantra. However, it is still accessible from the selected car via links, so may be relevant.
  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 bolts (A) and the expansion valve (B) from the evaporator core.

    Tightening torque: 

    7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)

    Fig 1: Identifying Expansion Valve
    G07257011Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
  5. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.
    Fig 2: Identifying Inlet And Outlet Heater Hoses
    G07257012Courtesy of HYUNDAI MOTOR CO.
    CAUTION: Engine coolant will run out 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.
  6. Remove the steering handle and column.

    (Refer to "STEERING COLUMN ")

  7. Remove the center console.

    (Refer to CONSOLE )

  8. Remove the cowl top cover.

    (Refer to "COWL TOP COVER ")

  9. Remove the photo sensor.

    (Refer to Photo Sensor)

  10. Loosen the cowl cross member mounting bolts (A).
    Fig 3: Identifying Cowl Cross Member Mounting Bolts
    G07257013Courtesy of HYUNDAI MOTOR CO.
  11. Remove the left & right front filler trim and than disconnect the connector (A).
    Fig 4: Identifying Connector (1 Of 2)
    G07257014Courtesy of HYUNDAI MOTOR CO.
    Fig 5: Identifying Connector (2 Of 2)
    G07257015Courtesy of HYUNDAI MOTOR CO.
  12. Disconnect the connectors and than remove the left & right multi box (A).
    Fig 6: Identifying Left & Right Multi Box (1 Of 2)
    G07257016Courtesy of HYUNDAI MOTOR CO.
    Fig 7: Identifying Left & Right Multi Box (2 Of 2)
    G07257017Courtesy of HYUNDAI MOTOR CO.
  13. Disconnect the main fuse box connectors (A).
    Fig 8: Identifying Main Fuse Box Connector
    G07257018Courtesy of HYUNDAI MOTOR CO.
  14. Remove the air duct (A) and then disconnect the air bag connector (B).
    Fig 9: Identifying Air Duct
    G07257019Courtesy of HYUNDAI MOTOR CO.
  15. Loosen the heater & blower unit mounting bolt (A).
    Fig 10: Identifying Heater & Blower Unit Mounting Bolt
    G07257020Courtesy of HYUNDAI MOTOR CO.
  16. Remove the heater & blower unit after loosening mounting bolts.
    Fig 11: Identifying Mounting Bolts
    G07257021Courtesy of HYUNDAI MOTOR CO.
  17. Loosen the cowl cross member mounting bolts (A) and than remove the crash pad and heater blower unit.
    Fig 12: Identifying Cowl Cross Member Mounting Bolts
    G07257022Courtesy of HYUNDAI MOTOR CO.
  18. Disconnect the connectors and than remove the heater blower unit (A) from crash pad.
    Fig 13: Identifying Heater Blower Unit
    G07257023Courtesy of HYUNDAI MOTOR CO.
  19. Remove the blower unit (A) from heater unit after loosening screws.
    Fig 14: Identifying Blower Unit
    G07257024Courtesy of HYUNDAI MOTOR CO.
  20. Loosen the mounting screw and then remove the heater core cover (A).
    Fig 15: Identifying Heater Core Cover
    G07257025Courtesy of HYUNDAI MOTOR CO.
  21. Disconnect the heater core (A) from heater unit.
    Fig 16: Identifying Heater Core
    G07257026Courtesy of HYUNDAI MOTOR CO.
  22. Loosen the heater unit lower case mount screw and then remove the heater unit lower case (A).
    Fig 17: Identifying Heater Unit Lower Case
    G07257027Courtesy of HYUNDAI MOTOR CO.
  23. Remove the evaporator core (A).
    Fig 18: Identifying Evaporator Core
    G07257028Courtesy of HYUNDAI MOTOR CO.
  24. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
  25. Installation is the reverse order of removal.
  26. 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. 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 the paint; if the refrigerant oil contacts the paint, wash it 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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