Repair Procedures: Replacement

Disconnect the negative (-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
When the engine is cool, drain the engine coolant from the radiator.
(Refer to ENGINE COOLING SYSTEM - 1.6L , ENGINE COOLING SYSTEM - 1.8L or ENGINE COOLING SYSTEM - 2.0L ).
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 1: Expansion Valve And Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
- When installing, replace with a new O-ring.
Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.
Tightening Torque:

7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)

Fig 2: Inlet And Outlet Heater Hoses
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 cowl top cover.
(Refer to "COWL TOP COVER ")
Remove the front wiper motor.
(Refer to "FRONT WIPER MOTOR ")
Remove the front seat assembly.
(Refer to "FRONT SEAT ASSEMBLY ")
Remove the front pillar trim.
(Refer to "FRONT PILLAR TRIM ")
Remove the floor console assembly.
(Refer to "FLOOR CONSOLE ASSEMBLY ")
Remove the shift lever assembly.
(Refer to MANUAL TRANSAXLE CONTROL SYSTEM - 1.6L or MANUAL TRANSAXLE CONTROL SYSTEM - 1.8L & 2.0L ).

(Refer to SHIFT LEVER 1.6L , SHIFT LEVER 1.8L or SHIFT LEVER 2.0L ).
Remove the cowl side trim.
(Refer to "COWL SIDE TRIM ")
Remove both sides of the crash pad side cover.
(Refer to "CRASH PAD SIDE COVER ")
Remove the crash pad lower panel.
(Refer to "CRASH PAD LOWER PANEL ")
Remove the steering wheel and column.
(Refer to "STEERING COLUMN AND SHAFT ")
Remove the glove box housing.
(Refer to "GLOVE BOX HOUSING ")
After loosening the mounting nut, remove the console duct (A).

Fig 3: Removing Console Duct
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the passenger compartment junction box connectors (A).

Fig 4: Passenger Compartment Junction Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the multi box connectors (A).
[Driver's Side]

Fig 5: Multi Box Connectors (Driver Side)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's Side]

Fig 6: Multi Box Connectors (Passenger Side)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the airbag control module (SRSCM) connector (A).

Fig 7: Airbag Control Module Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the wiring mounting clips (A).
Disconnect the shift lever connector (B).

Fig 8: Shift Lever Connector And Wiring Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connectors (A) and the mounting clips in the front pillar.
[Passenger's Side]

Fig 9: Front Pillar Connector (Passenger Side)
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the mounting bolts.

Fig 10: Front Pillar Connector Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the cowl cross member assembly mounting bolts (A).

Fig 11: Cowl Cross Member Assembly Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the drain hose fixing clip under the vehicle.
Disconnect the heater and blower unit connectors.
Remove the heater & blower unit (A) from the crash pad after loosening the mounting nuts.

Fig 12: Heater And Blower Unit
Courtesy of KIA MOTORS AMERICA, INC.
Separate the blower unit from the heater unit after loosening the screws.

Fig 13: Blower Unit To Heater Unit Assembly Screws Locations
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.