Complete replacement of the AC evaporator core, requiring full dashboard removal and AC system recovery and recharge on a 2015 Kia Forte with 1.8L engine.

Warnings

Tools required

Parts

• AC Evaporator Core × 1 — Use OEM specification
• AC Line O-rings (kit) × 1 — Use OEM specification
• Expansion Valve × 1 — Use OEM specification (recommended replacement)
• Receiver Drier × 1 — Use OEM specification (mandatory replacement)
• PAG 46 Oil × 1 — Use OEM specification
• R-134a Refrigerant × 1 — Approximately 24-28 oz
• Dashboard fastener clips (assorted) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Disconnect negative battery cable and wait minimum 3 minutes for airbag system discharge
3. Recover AC refrigerant using certified recovery machine and document amount removed
4. Remove both front seats for easier dashboard access (4 bolts per seat, unplug electrical connectors)
5. Remove steering wheel using appropriate puller after removing airbag module
6. Drain coolant from radiator to prevent spills when disconnecting heater hoses
7. Take detailed photos of dashboard wiring harness routing and connector locations

Procedure

1. 1

   Disconnect AC Lines at Firewall
   Locate the AC line connections at the engine compartment firewall. Remove the bolts securing the AC lines to the evaporator. Cap all open fittings immediately with plugs to prevent moisture entry and contamination. Remove and discard all old O-rings from fittings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
2. 2

   Remove Lower Dashboard Components
   Remove the lower driver side panel, knee bolster, and center console. Disconnect the OBD-II port connector and any attached wiring. Remove the lower passenger side panel and glove box assembly by releasing the damper arms and removing retaining screws. Disconnect glove box light connector.
3. 3

   Remove Steering Column and Instrument Cluster
   Lower steering column by removing 4 mounting bolts. Disconnect all electrical connectors including clock spring, ignition switch, and column switches. Remove instrument cluster by removing trim bezel and 4 retaining screws. Carefully pull cluster out and disconnect all connectors on the back.
   ⚠Support steering column weight to prevent dropping and damaging clock spring or shift interlock cable.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
4. 4

   Disconnect Dashboard Wiring and HVAC Controls
   Remove center stack trim panel and climate control assembly. Disconnect all electrical connectors from HVAC controls, radio, and hazard switch. Label all connectors for reassembly. Disconnect main dashboard wiring harness connectors behind instrument cluster area.
5. 5

   Remove Dashboard Mounting Hardware
   Locate and remove all dashboard mounting bolts (typically 8-10 bolts along top edge, sides, and center). Remove the side defroster vent grilles to access upper mounting bolts. Check for any remaining fasteners or clips before attempting to remove dashboard.
   Torque spec

   Mounting Bolts26 Nm (19 lb-ft)
6. 6

   Remove Dashboard Assembly
   With all fasteners removed and connectors disconnected, carefully pull dashboard rearward. Have an assistant support the passenger side. Work the dashboard free from any remaining clips. Tilt dashboard as needed to clear steering column opening and remove from vehicle.
   ⚠Dashboard is heavy and awkward. Use two people and protect windshield from scratches during removal.
7. 7

   Access and Remove HVAC Housing Covers
   With dashboard removed, the HVAC housing is now visible on the firewall. Remove the blower motor assembly by disconnecting electrical connector and removing mounting screws. Remove any covers or access panels from the HVAC housing to access the evaporator case.
   Torque spec

   Cover Screws10 Nm (8 lb-ft)
8. 8

   Open Evaporator Case
   Remove the screws securing the evaporator case halves. Carefully separate the case halves, noting the position of any foam seals or gaskets. The expansion valve will be visible on the inlet line to the evaporator.
   Torque spec

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

   Remove Expansion Valve and Old Evaporator
   Disconnect the expansion valve from the evaporator inlet. Remove the temperature sensor from the evaporator fins. Carefully lift the old evaporator out of the case, noting the orientation and position of any foam seals or insulation pads. Inspect case for debris or contamination.
   ℹ️Check old evaporator for signs of leak location and inspect case drain tube for blockages.
   Torque spec

   Expansion Valve10 Nm (7 lb-ft)
10. 10

    Prepare and Install New Evaporator
    Add 2-3 oz of fresh PAG 46 oil to the new evaporator core (pour into inlet/outlet tubes). Install new or cleaned foam seals on evaporator. Position new evaporator in case with correct orientation matching original installation. Install temperature sensor into evaporator fins in same location as original.
    ⚠Use only manufacturer-specified PAG oil. Wrong oil type will damage compressor.
11. 11

    Install Expansion Valve with New O-rings
    Install new O-rings on expansion valve connection (lubricate with PAG oil). Connect expansion valve to evaporator inlet tube and torque to specification. Verify proper seating of O-rings and cleanliness of all connections.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
12. 12

    Close and Seal Evaporator Case
    Ensure all foam seals are properly positioned. Join the evaporator case halves together, ensuring proper alignment. Install and torque all case screws in a cross-pattern to ensure even sealing. Reinstall any covers and blower motor assembly.
    Torque spec

    Evaporator Case Screws5 Nm (4 lb-ft)

    Cover Screws10 Nm (8 lb-ft)
13. 13

    Reconnect AC Lines at Firewall
    Install new lubricated O-rings on all AC line fittings (coat with PAG oil). Connect AC lines to evaporator tubes at firewall. Torque all AC line fittings to specification. Verify proper seating and alignment of all connections.
    ⚠Never reuse old O-rings. All O-rings must be replaced and lubricated with PAG oil before installation.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
14. 14

    Reinstall Dashboard Assembly
    With assistance, position dashboard into vehicle. Route all wiring harnesses to correct locations. Align dashboard with mounting points and install all mounting bolts finger-tight first, then torque in sequence from center outward. Reconnect all electrical connectors, HVAC controls, instrument cluster, and steering column.
    Torque spec

    Mounting Bolts26 Nm (19 lb-ft)
15. 15

    Evacuate and Recharge AC System
    Connect AC service machine to both high and low side ports. Evacuate system to deep vacuum (29+ inches Hg) for minimum 30-45 minutes to remove all moisture. Perform vacuum hold test for 15 minutes to verify no leaks. Recharge system with correct amount of R-134a refrigerant (approximately 24-28 oz, verify on underhood label) and add additional PAG oil if needed per service machine calculation.
    ⚠️System must be evacuated for minimum 30 minutes to remove moisture that will cause compressor failure. Verify vacuum holds before charging.

Reassembly

1. Reinstall all dashboard trim panels, glove box, center console, and lower panels in reverse order of removal
2. Reinstall steering wheel with proper clock spring alignment and torque airbag module fasteners correctly
3. Reinstall both front seats and reconnect all electrical connectors
4. Reconnect negative battery cable and set clock/radio presets
5. Refill coolant system if heater hoses were disconnected during access
6. Replace receiver drier as moisture exposure during evaporator replacement requires new drier

Verification

• Start engine and turn AC to maximum cold with high blower speed
• Verify both low and high side pressures are within specification (typically 25-35 psi low, 200-250 psi high at idle with 80°F ambient)
• Check center vent temperature reaches 38-42°F within 5 minutes of operation
• Inspect all AC line connections at firewall for leaks using leak detector
• Verify no refrigerant odor in cabin and evaporator drain tube is dripping condensate
• Test all dashboard functions, switches, lights, and gauges for proper operation
• Check for any dashboard rattles or loose trim pieces
• Verify no airbag warning lights on instrument cluster after battery reconnection

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