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:
1. Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
2. Since the electric compressor uses high-voltage, you should use PVE or POE oil which have high Volumetric Resistivity.
3. If the PVE or 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: Locating Expansion Valve Cover
Courtesy of KIA MOTORS AMERICA, INC.
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: Removing Expansion Valve Bolts From Evaporator Core
Courtesy of KIA MOTORS AMERICA, INC.

CAUTION: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
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 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.
Remove the center console.
(Refer to - "Center Console .")
Remove the shift lever housing assembly.
(Refer to - "Shift Lever .")
Remove the steering handle and column.
(Refer to - "Steering Column .")
Loosen the cowl cross member mounting bolts (A).

Fig 4: Loosening Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the front pillar trim and then disconnect the connector (A).

Fig 5: Locating Front Pillar Trim (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 6: Locating Connector (A) (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the air bag connector (A).

Fig 7: Disconnecting Air Bag Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the cowl side trim and then disconnect the connectors (A).

Fig 8: Removing Cowl Side Trim And Disconnecting Connectors (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 9: Removing Cowl Side Trim And Disconnecting Connectors (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the fuse box connector (B).

Fig 10: Locating Fuse Box Connector
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the heater & blower unit mounting bolts.

Fig 11: Loosening Heater And Blower Unit Mounting Bolts (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 12: Loosening Heater And Blower Unit Mounting Bolts (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the cowl cross member mounting bolts (A) and then remove the crash pad and heater blower unit (B).

Fig 13: Locating Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connectors and then remove the heater blower unit (A) from crash pad.

Fig 14: Removing Heater Blower Unit From Crash Pad
Courtesy of KIA MOTORS AMERICA, INC.
Remove the blower unit (A) from heater unit after loosening screws.

Fig 15: Removing Blower Unit Screws From Heater Unit (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 16: Removing Blower Unit Screws From Heater Unit (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the mounting screw and then remove the heater core cover (A).

Fig 17: Removing Heater Core Cover Mounting Screws
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater core (A) from heater unit.

Fig 18: Disconnecting Heater Core From Heater Unit
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the mounting screws and then remove the heater unit lower case (A).

Fig 19: Loosening Heater Unit Lower Case Mounting Screws
Courtesy of KIA MOTORS AMERICA, INC.
Remove the evaporator core (A).

Fig 20: Locating Evaporator Core
Courtesy of KIA MOTORS AMERICA, INC.
Installation is the reverse order of removal. 25. Installation is the reverse order of removal, and note these items:

If you're installing a new evaporator, add refrigerant oil. (PVE or POE OIL)
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.
Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
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
Apply sealant to the grommets.
Make sure that there is no air leakage.
Charge the system and test its performance.
Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
Refill the cooling system with engine coolant