Complete replacement of the AC evaporator core, requiring dashboard removal, refrigerant recovery, and system recharge.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Use OEM specification
• Expansion valve × 1 — Use OEM specification
• AC line O-rings × 6 — Multiple sizes needed
• Evaporator temperature sensor × 1 — Use OEM specification
• Receiver-drier × 1 — Replace whenever system is opened
• PAG oil for AC system × 1 — PAG 46 oil
• R-134a refrigerant × 1 — System capacity approximately 1.43 lbs
• Evaporator case foam seal × 1 — Use OEM specification

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 1.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
3. Recover AC refrigerant using approved recovery machine and record amount removed
4. Drain engine coolant to below heater core level using radiator drain valve
5. Remove front seats to provide working space (4 bolts per seat, disconnect electrical connectors)
6. Disconnect positive battery terminal and remove battery from vehicle
7. Remove windshield wiper arms and cowl cover panel
8. Take extensive photographs of dashboard harness routing and connections for reference

Procedure

1. 1

   Remove steering wheel and column covers
   Disconnect steering wheel harness (horn, airbag, cruise control). Remove steering wheel bolt and use steering wheel puller to remove wheel. Remove upper and lower column covers by removing screws and releasing clips.
2. 2

   Remove instrument cluster and center console
   Remove instrument cluster bezel and disconnect cluster harness. Remove 4 cluster mounting screws and pull cluster out. Remove center console starting from rear (cupholder area), working forward. Remove gear selector trim, disconnect electrical connectors, and remove console mounting bolts.
3. 3

   Disconnect dashboard harnesses and components
   Disconnect all dashboard electrical connectors including: BCM connectors (driver side), climate control connectors, passenger airbag connector, blower motor connector, evaporator temperature sensor, and all other visible harnesses. Label each connection with tape and marker. Remove glove box assembly completely.
4. 4

   Disconnect heater core and AC lines at firewall
   From engine bay, disconnect heater hoses at firewall (use hose clamp pliers). Disconnect AC lines at firewall connection points. Cap all open AC lines immediately to prevent moisture entry. Allow residual coolant to drain into pan.
   ⚠Hot coolant may still be present in heater core lines even after draining radiator.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove dashboard mounting bolts and brackets
   Remove dashboard mounting bolts at sides (near A-pillars), center support bracket bolts, and lower mounting points near footwells. There are typically 10-12 mounting bolts total. Remove any remaining ground straps. Remove cross-car support beam behind dashboard if equipped.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
6. 6

   Remove dashboard assembly
   With helper supporting dashboard, carefully pull dashboard rearward and lift out of vehicle. Watch for any remaining wire harness connections or clips. Dashboard is heavy and awkward; requires two people. Place on protected surface away from work area.
7. 7

   Access and remove HVAC case assembly
   Remove blower motor assembly (disconnect electrical, remove mounting screws). Remove HVAC case mounting bolts and screws securing case to firewall and support brackets. There are approximately 8-10 fasteners. Carefully pull entire HVAC case assembly away from firewall.
   ℹ️HVAC case is bulky but not extremely heavy. May require tilting to clear steering column support.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
8. 8

   Disassemble HVAC case
   Place HVAC case on clean workbench. Remove case cover screws around perimeter. Carefully separate upper and lower case halves, noting position of blend door actuators and linkages. Remove expansion valve from evaporator inlet.
   ⚠Case halves are sealed with foam gasket. Separate carefully to avoid breaking plastic tabs.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)

   Evaporator Case Screws5 Nm (4 lb-ft)
9. 9

   Remove old evaporator and expansion valve
   Lift old evaporator core out of lower case half. Remove and discard old expansion valve. Inspect evaporator case for debris, leaves, or moisture damage. Vacuum out any debris. Check blend doors and actuator operation while case is open.
10. 10

    Install new evaporator and expansion valve
    Install new expansion valve on new evaporator inlet tube using new O-rings lubricated with PAG oil. Add 2 oz of fresh PAG 46 oil into evaporator inlet to replace oil lost with old evaporator. Position new evaporator in lower case half, ensuring temperature sensor grommet seats properly. Install new case foam seals.
    ℹ️Expansion valve must be oriented correctly with sensing bulb contacting evaporator outlet tube.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
11. 11

    Reassemble HVAC case
    Verify all blend door linkages are properly positioned. Join upper and lower case halves carefully, ensuring foam seal seats evenly. Install and tighten evaporator case screws in cross-pattern to specified torque. Reinstall cover screws. Connect evaporator temperature sensor.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws11 Nm (8 lb-ft)
12. 12

    Reinstall HVAC case assembly to vehicle
    Position HVAC case assembly back into vehicle, aligning with firewall openings. Install mounting bolts and tighten to specification. Reinstall blower motor assembly and connect electrical connector. Verify all case mounting points are secure.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
13. 13

    Reinstall dashboard assembly
    With helper, carefully position dashboard back into vehicle. Align with mounting points and slide forward onto studs/clips. Install all dashboard mounting bolts and tighten to specification. Reconnect all electrical harnesses using photographs as reference. Reinstall cross-car support beam if removed.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)
14. 14

    Connect AC and heater lines at firewall
    Install new O-rings on AC line fittings, lubricate with PAG oil. Connect AC lines at firewall and torque to specification. Connect heater hoses and secure with new clamps. Remove caps from open AC lines only immediately before connection.
    ⚠Ensure O-rings are properly seated before tightening fittings to avoid leaks.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
15. 15

    Complete interior reassembly
    Reinstall instrument cluster, steering column covers, and steering wheel. Reinstall center console assembly and all trim panels. Reinstall glove box. Reinstall front seats and connect electrical connectors. Reinstall battery, cowl cover, and wiper arms.

Reassembly

1. Refill cooling system with Hyundai/Kia Long Life Coolant to proper level
2. Bleed cooling system by running engine with heater on high until thermostat opens
3. Evacuate AC system to 29+ inches vacuum for minimum 45 minutes to remove moisture
4. Verify vacuum holds for 10 minutes without decay before charging
5. Recharge AC system with R-134a to specification (approximately 1.43 lbs total)
6. Add UV dye to AC system for future leak detection if desired
7. Verify all dashboard functions operate correctly: gauges, lights, climate controls, airbag light

Verification

• Start engine and verify no coolant leaks at heater core connections
• Test AC system: should produce 38-42°F air at center vents with 95°F ambient
• Check AC pressures: approximately 25-35 psi low side, 175-250 psi high side at idle (varies with ambient temperature)
• Use leak detector to check all AC line connections for leaks
• Verify blower motor operates at all speed settings
• Test temperature blend door operation from full cold to full hot
• Verify all dashboard electrical functions work properly including airbag system (no warning lights)
• Test drive vehicle and verify AC performance under load
• Check for proper airflow distribution in all modes (panel, bi-level, floor, defrost)

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