Repair Procedures: Replacement

CAUTION:

Put on gloves to protect your hands.

NOTE:

When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
Take care not to bend or scratch the trim and panels.

Disconnect the negative (-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
When the engine is cool, drain the engine coolant from the radiator.
(Refer to ENGINE COOLING SYSTEM - 1.6L ) or (refer to ENGINE COOLING SYSTEM - 2.0L )
Remove the cowl top cover.
(Refer to COWL TOP COVER )
Remove the bolts and the expansion valve (A) 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 1: Expansion Valve
Courtesy of KIA MOTORS AMERICA, INC.
Remove the expansion valve flange (A) after loosening the screws.

Fig 2: Expansion Valve Flange
Courtesy of KIA MOTORS AMERICA, INC.
NOTE:
- Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
- When installing, replace with a new O-ring (B).
Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.

Fig 3: Heater Unit Inlet And Outlet Hoses
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- When disconnecting the hoses, engine coolant will pour out of the hose. So drain the coolant into a clean drip pan.
Remove the inlet and outlet heater hoses flange (A) after loosening the nuts (B).

Fig 4: Inlet And Outlet Heater Hoses Flange And Nuts
Courtesy of KIA MOTORS AMERICA, INC.

Fig 5: Inlet And Outlet Heater Hoses Flange
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the cowl cross member mounting bolts (A).

Fig 6: Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove both sides of front seat assembly.
(Refer to "FRONT SEAT ASSEMBLY ")
Remove the main crash pad assembly.
(Refer to "MAIN CRASH PAD ASSEMBLY ")
Disconnect the steering column connectors.
(Refer to "STEERING COLUMN AND SHAFT ")
Lower the steering column after loosening the mounting bolts.
(Refer to "STEERING COLUMN AND SHAFT ")
Remove the rear air duct assembly (A).

Fig 7: Removing Rear Air Duct Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift lever assembly.
(Refer to SHIFT LEVER 1.6L ) or (refer to SHIFT LEVER 2.0L )
Disconnect the airbag control module (SRSCM) connector (A).

Fig 8: Airbag Control Module Connector
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the mounting bolts and nuts, then remove the cowl cross bar center bracket (A).

Fig 9: Cowl Cross Bar Center Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the passenger compartment junction box connectors (A).

Fig 10: Passenger Compartment Junction Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Remove the passenger compartment junction box mounting clips (A).

Fig 11: Passenger Compartment Junction Box Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the multi box connectors (A).
[Driver's]

Fig 12: Multi Box Connectors (Driver's)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 13: Multi Box Connectors (Passenger's)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]

Fig 14: Front Pillar Connector And Mounting Clips (Driver's)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 15: Front Pillar Connector And Mounting Clips (Passenger's)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drain hose (A).

Fig 16: Drain Hose
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the nuts and bolts remove the cowl cross bar and heater & blower unit (A) together.

Fig 17: Cowl Cross Bar And Heater & Blower Unit
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater & blower unit connectors.
1. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
  
  Fig 18: Intake Actuator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the blower motor (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring mounting clips.
  
  Fig 19: Blower Motor, Temperature Control Actuator & Mode Control Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the evaporator temperature sensor (A) field effect transistor air conditioning resistor (B) connectors and then remove the wiring mounting clips.
  
  Fig 20: Evaporator Temperature Sensor & Air Conditioning Resistor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
  
  Fig 21: Cluster Ionizer Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the heater & blower unit wiring mounting clips (A).
  
  Fig 22: Heater & Blower Unit Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
Loosen the heater and blower unit mounting bolts (A) and then remove the mounting clips (B).

Fig 23: Heater And Blower Unit Mounting Bolts And Clips
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.

Fig 24: Heater And Blower Unit & Cowl Cross Bar
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.
Information
- Make sure the crash pad fits onto the guide pins correctly.
- Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
- Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
- Enter the anti-theft code for the radio, then enter the customers radio station presets.