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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2013 Kia Sportage and 2012 Kia Sportage. 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 expansion valve cover (A).
    Fig 1: Expansion Valve Cover
    G07425052Courtesy of KIA MOTORS AMERICA, INC.
  5. 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 lb-ft)

    Fig 2: Expansion Valve & Mounting Bolts
    G07425053Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
  6. Remove the expansion valve flange (A).
    Fig 3: Expansion Valve Flange
    G07425054Courtesy of KIA MOTORS AMERICA, INC.
  7. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.
    Fig 4: Identifying Inlet & Outlet Heater Hoses
    G07425055Courtesy of KIA MOTORS AMERICA, INC.
    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.
  8. Remove the cowl top cover.

    Refer to "COWL TOP COVER ".

  9. Loosen the cowl cross member mounting bolts (A).
    Fig 5: Cowl Cross Member Mounting Bolts
    G07425056Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove the steering handle and column.

    Refer to "STEERING COLUMN ".

  11. Remove the center console.

    Refer to CONSOLE .

  12. Disconnect the airbag connector (A).
    Fig 6: Identifying Airbag Connector
    G07425057Courtesy of KIA MOTORS AMERICA, INC.
  13. Disconnect the connectors and then remove the left & right multi box (A).
    Fig 7: Identifying Left Multi Box
    G07425058Courtesy of KIA MOTORS AMERICA, INC.
    Fig 8: Identifying Right Multi Box
    G07425059Courtesy of KIA MOTORS AMERICA, INC.
  14. Remove the left & right filler trim and than disconnect the connector (A).
    Fig 9: Identifying Left Filler Trim Connector
    G07425060Courtesy of KIA MOTORS AMERICA, INC.
    Fig 10: Identifying Right Filler Trim Connector
    G07425061Courtesy of KIA MOTORS AMERICA, INC.
  15. Remove the heater & blower unit after loosening mounting bolts (A).
    Fig 11: Identifying Heater & Blower Unit Mounting Bolts
    G07425062Courtesy of KIA MOTORS AMERICA, INC.
  16. Loosen the cowl cross member mounting bolts (A) and then remove the crash pad and heater blower unit.
    Fig 12: Identifying Cowl Cross Member Mounting Bolts
    G07425063Courtesy of KIA MOTORS AMERICA, INC.
  17. Disconnect the connectors and then remove the heater blower unit (A) from crash pad.
    Fig 13: Identifying Heater Blower Unit
    G07425064Courtesy of KIA MOTORS AMERICA, INC.
  18. Remove the blower unit (A) from heater unit (B) after loosening screws.
    Fig 14: Identifying Blower Unit
    G07425065Courtesy of KIA MOTORS AMERICA, INC.
    Fig 15: Identifying Heater Unit
    G07425066Courtesy of KIA MOTORS AMERICA, INC.
  19. Loosen the mounting screw and then remove the heater core cover (A).
    Fig 16: Heater Core Cover & Mounting Screws
    G07425067Courtesy of KIA MOTORS AMERICA, INC.
  20. Disconnect the heater core (A) from heater unit.
    Fig 17: Identifying Heater Core
    G07425068Courtesy of KIA MOTORS AMERICA, INC.
  21. Loosen the heater unit lower case mount screw and then remove the heater unit lower case (A).
    Fig 18: Identifying Heater Unit Lower Case
    G07425069Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the evaporator core (A).
    Fig 19: Identifying Evaporator Core
    G07425070Courtesy of KIA MOTORS AMERICA, INC.
  23. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
  24. Installation is the reverse order of removal.
  25. 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 them. 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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