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Heater Unit: Replacement

WARNING: This page is about a different car, the 2008 Hyundai Tucson. However, it is still accessible from the selected car via links, so may be relevant.
  1. Recover the refrigerant with a recovery/recycling/charging station (see REFRIGERANT RECOVERY ).
  2. When the engine is cool, drain the engine coolant from the radiator.
  3. Disconnect the negative cable from the battery.
  4. 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.

  5. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.

    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.

    Fig 1: Identifying Bolts, Expansion Valve, Inlet Hose & Outlet Hose
    G03764768Courtesy of HYUNDAI MOTOR CO.
  6. Remove the crash pad (see CRASH PAD ).
  7. Remove the cross member.
  8. Remove the mounting nut (A), the mounting bolts (B) and heater & evaporator unit (C).
    Fig 2: Identifying Mounting Nut, Mounting Bolt, & Heater & Evaporator Unit
    G03764769Courtesy of HYUNDAI MOTOR CO.
  9. Remove the self-tapping screws (A) and the cover (B).
  10. Remove the side bracket (C).
    11. Fig 3: Identifying Self-Tapping Screws, Cover & Side Bracket
    G03764770Courtesy of HYUNDAI MOTOR CO.
  11. Remove the clip and lower cover.

    Be careful not to bend the inlet and outlet pipes during heater core and evaporator core removal.

  12. Install the heater core and evaporator core in the reverse order of removal.
  13. Install in the reverse order of removal, and note these items:
    • If you're installing a new evaporator, add refrigerant 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 (see SYSTEM CHARGING ), and test its performance (see INSPECT FOR LEAKAGE OF REFRIGERANT ).
    • Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
    • Refill the cooling system with engine coolant.
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