This procedure involves removing the dashboard and HVAC housing to access and replace the heater core in a 2016-2024 Hyundai Tucson with the 2.5L I4 AWD engine.

Warnings

Tools required

Parts

• Heater core × 1 — Use OEM specification
• Heater core O-rings/seals × 1 — Included with heater core kit
• Dashboard trim clips × 10 — Replace broken clips as needed
• Coolant drain plug gasket × 1 — 21513-23001 or equivalent

Fluids

• Hyundai/Kia Long Life Coolant (Green) — 10 qt

Preparation

1. Ensure engine is completely cold (minimum 2 hours after operation)
2. Disconnect negative battery terminal and wait 3 minutes for airbag system discharge
3. Position drain pan under radiator drain plug and drain coolant completely
4. Remove engine splash shield to access heater hoses from underneath
5. Take detailed photos of dashboard and center console from multiple angles

Procedure

1. 1

   Drain coolant and disconnect heater hoses
   With engine cold, open radiator drain plug and drain coolant into appropriate container. Locate heater hoses at firewall in engine bay (driver side). Release hose clamps using hose clamp pliers and disconnect both heater hoses from heater core inlet/outlet tubes. Cap or plug hoses to prevent coolant spillage. Place towels inside vehicle at firewall to catch residual coolant.
   Torque spec

   Heater Hose Clamps3 Nm (2 lb-ft)
2. 2

   Remove center console and lower trim panels
   Remove front cup holder by lifting firmly upward. Remove center console side covers using panel removal tool. Remove all accessible screws from center console (typically 4-6 screws). Disconnect shift knob wiring connector on automatic transmission. Lift center console rearward and up to remove. Remove lower driver and passenger kick panels by releasing push clips.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
3. 3

   Remove steering column covers and instrument cluster bezel
   Remove upper and lower steering column covers by releasing retaining screws and clips. Remove instrument cluster bezel by carefully prying at edges with panel tool. Disconnect any electrical connectors for warning lights or switches integrated into bezel. Set aside in protected area.
   Torque spec

   Dashboard Screws3 Nm (2 lb-ft)
4. 4

   Disconnect main dashboard electrical connectors
   Working from driver side, locate and disconnect main instrument cluster connector (large multi-pin connector behind gauge cluster). Disconnect HVAC control panel connectors, radio/infotainment connectors, and all switch connectors in dashboard. Label each connector with tape or take reference photos. Disconnect passenger airbag connector (yellow connector) - handle with care.
   ⚠Airbag connectors are yellow and must be handled carefully. Ensure battery has been disconnected for at least 3 minutes before touching airbag connectors.
5. 5

   Remove dashboard mounting bolts
   Locate dashboard mounting bolts at driver side (typically 2 bolts near fuse panel area), center (2-3 bolts behind center stack), and passenger side (2 bolts). Remove all dashboard mounting bolts. Check for any remaining screws securing dashboard to firewall or A-pillars. Dashboard should now be free to move.
   Torque spec

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

   Remove dashboard assembly
   With assistant supporting passenger side, carefully pull dashboard away from firewall. Guide dashboard over steering column while lifting slightly. Watch for any missed electrical connectors or fasteners that may still be attached. Once clear, remove dashboard completely from vehicle and place on protected work surface. Cover open interior areas with clean towels.
   ℹ️Dashboard is heavy and awkward. Two people are strongly recommended for removal and installation to prevent damage.
7. 7

   Access and remove HVAC housing bolts
   With dashboard removed, HVAC housing is now visible. Disconnect any remaining electrical connectors to blower motor and actuators on HVAC housing. Remove HVAC housing mounting bolts (typically 6-8 bolts securing housing to firewall and support brackets). Note location of ground wires attached to housing bolts.
   Torque spec

   Housing Bolts14 Nm (10 lb-ft)
8. 8

   Separate HVAC housing halves
   Remove screws securing upper and lower HVAC housing halves together (typically 8-12 screws around perimeter). Carefully separate housing halves. Upper half typically lifts away to expose heater core, evaporator, and blend doors. Place upper housing half aside in clean area.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
9. 9

   Remove heater core from housing
   Locate heater core mounting bracket or retaining clips inside lower HVAC housing. Remove heater core mounting fasteners. Carefully slide heater core out of housing, noting orientation and position. Inspect heater core tubes for any remaining coolant. Check housing for debris, leaves, or blockages and clean as needed.
   Torque spec

   Heater Core Mounting8 Nm (6 lb-ft)
10. 10

    Install new heater core
    Install new O-rings or seals onto heater core tubes (typically included with replacement heater core). Carefully slide new heater core into HVAC housing in same orientation as original. Ensure heater core tubes align properly with firewall openings. Install heater core mounting fasteners and torque to specification.
    ⚠Ensure heater core tubes are properly sealed with new O-rings to prevent coolant leaks inside vehicle.
    Torque spec

    Heater Core Mounting8 Nm (6 lb-ft)
11. 11

    Reassemble HVAC housing
    Position upper HVAC housing half onto lower half, ensuring all blend door linkages and actuator connections align properly. Install housing screws around perimeter and torque to specification. Verify all actuators move freely and are not binding.
    Torque spec

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

    Install HVAC housing to firewall
    Position complete HVAC housing assembly against firewall, aligning heater core tubes with firewall penetrations. Install housing mounting bolts with any ground wires in original locations. Torque housing bolts to specification. Reconnect all electrical connectors to blower motor and actuators.
    Torque spec

    Housing Bolts14 Nm (10 lb-ft)
13. 13

    Reinstall dashboard assembly
    With assistant, position dashboard assembly over steering column and guide into place against HVAC housing. Ensure all wiring harnesses are routed properly and not pinched. Install dashboard mounting bolts and torque to specification. Reconnect all electrical connectors in reverse order of removal, referring to photos taken during disassembly.
    Torque spec

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

    Reconnect heater hoses and refill coolant
    Working in engine bay, reconnect heater hoses to heater core tubes at firewall. Install hose clamps and torque to specification. Close radiator drain plug with new gasket. Refill cooling system with Hyundai/Kia Long Life Coolant (Green) to proper level. Use coolant funnel to prevent air pockets.
    Torque spec

    Heater Hose Clamps3 Nm (2 lb-ft)
15. 15

    Bleed cooling system and test operation
    With heater controls set to maximum heat and fan off, start engine and allow to reach operating temperature. Monitor coolant level and add as needed. Squeeze upper radiator hose to help purge air from system. Once engine reaches operating temperature, turn on heater fan and verify hot air output. Check heater core tube connections at firewall for leaks. Top off coolant to proper level in overflow tank.
    ⚠Monitor engine temperature closely during initial bleeding. If temperature rises above normal, shut off engine immediately and allow to cool.

Reassembly

1. Reinstall instrument cluster bezel, steering column covers, and all dashboard trim pieces in reverse order of removal
2. Reinstall center console, ensuring all electrical connectors are properly seated
3. Reinstall lower kick panels and verify all clips are fully engaged
4. Reinstall engine splash shield
5. Reconnect negative battery terminal and recalibrate power window auto functions if needed

Verification

• Start engine and verify heater produces hot air at all fan speeds within 5-10 minutes of operation
• Check for coolant leaks at heater hose connections at firewall, both with engine cold and at operating temperature
• Verify coolant level remains stable in overflow tank after multiple heat cycles
• Test all dashboard controls, gauges, and warning lights function properly
• Verify no coolant smell or dampness on passenger side floor carpet
• Confirm HVAC blend doors operate correctly by testing full range from cold to hot air

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