Repair Procedures: Replacement

WARNING: This page is about a different variant/trim than selected.

Disconnect the negative (-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
CAUTION:
- Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
- Since the electric compressor uses high-voltage, you should use POE oil which have high volumetric resistivity.
- If the POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.
When the engine is cool, drain the engine coolant from the radiator.
Remove the expansion valve cover (A).

Fig 1: Identifying Expansion Valve Cover
Courtesy of HYUNDAI MOTOR AMERICA
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.

Tightening torque: 7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)

Fig 2: Removing Bolts And Expansion Valve From Evaporator Core
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.

Fig 3: Disconnecting Inlet And Outlet Heater Hoses From Heater Unit
Courtesy of HYUNDAI MOTOR AMERICA

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.
Remove the crash pad.
(Refer to "CRASH PAD ")
Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator temperature sensor.
Remove the cowl cross bar assembly.
(Refer to "COWL CROSS BAR ")
Remove the heater & blower unit (A) after loosening 3 mounting bolts.

Fig 4: Removing Heater & Blower Unit Mounting Bolts
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Remove the blower unit (A) from heater unit after loosening 3 screws.

Fig 5: Removing Blower Unit From Heater Unit
Courtesy of HYUNDAI MOTOR AMERICA

Fig 6: Removing Blower Unit From Heater Unit Screw
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Loosen the mounting screw and then remove the heater core cover (A).

Fig 7: Removing Heater Core Cover Mounting Screw
Courtesy of HYUNDAI MOTOR AMERICA
Remove the heater core (A) from heater unit.

Fig 8: Removing Heater Core From Heater Unit
Courtesy of HYUNDAI MOTOR AMERICA
Loosen the heater unit lower case mounting screw and then remove the heater unit lower case (A).

Fig 9: Loosening Heater Unit Lower Case Mounting Screw
Courtesy of HYUNDAI MOTOR AMERICA
Remove the evaporator core (A).

Fig 10: Identifying Evaporator Core
Courtesy of HYUNDAI MOTOR AMERICA
Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
Install in the reverse order or removal, and note these items:
1. If you're installing a new evaporator, add refrigerant oil (POE OIL).
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