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Repair Procedures: Replacement

WARNING: This page is about a different variant/trim than selected.
  1. Disconnect the negative (-) battery terminal.
  2. Recover the refrigerant with a recovery/recycling/charging station.
  3. When the engine is cool, drain the engine coolant from the radiator.

    (Refer to Engine Mechanical System - "COOLANT ")

  4. Remove the cowl top cover.

    (Refer to Body - "COWL TOP COVER (EXCEPT HEV) ")

  5. Remove the expansion valve cover (A) after loosening the nut.

    Tightening torque:  8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb.ft)

    Fig 1: Locating Expansion Valve Cover With Nut
    G12145066Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the expansion valve (A) from the evaporator core after loosening the bolts.

    Tightening torque:  8.8 - 13.7 N.m (0.9 - 1.4 kgf.m, 6.5 - 10.1 lb.ft)

    Fig 2: Locating Expansion Valve With Bolts
    G12145067Courtesy of KIA MOTORS AMERICA, INC.
    NOTE:
    • Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
    • When installing, replace with a new O-ring (B).
  7. Remove the air cleaner assembly.

    (Refer to Engine Mechanical System - "AIR CLEANER ")

  8. Disconnect the heater hoses (A).
    Fig 3: Locating Heater Hoses
    G12145068Courtesy 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.
  9. Loosen the cowl cross member mounting bolts (A).
    Fig 4: Locating Cowl Cross Member Mounting Bolts
    G12145069Courtesy of KIA MOTORS AMERICA, INC.
  10. Remove both sides of front seat assembly.

    (Refer to Body - "FRONT SEAT ASSEMBLY ")

  11. Remove the floor console.

    (Refer to Body - "FLOOR CONSOLE ")

  12. Remove both sides of the front pillar trim.

    (Refer to Body - "FRONT PILLAR TRIM ")

  13. Remove both sides of the cowl side trim.

    (Refer to Body - "COWL SIDE TRIM ")

  14. Remove the crash pad lower panel.

    (Refer to Body - "CRASH PAD LOWER PANEL ")

  15. Remove the steering column shroud lower panel.

    (Refer to Body - "STEERING COLUMN SHROUD PANEL ")

  16. Remove the steering wheel.

    (Refer to Steering System - "STEERING WHEEL ")

  17. Remove the multifunction switch.

    (Refer to Body Electrical System - "MULTIFUNCTION SWITCH ")

  18. Lower the steering column after loosening the mounting bolts.

    (Refer to Steering System - "STEERING COLUMN AND SHAFT ")

  19. Remove the front door scuff trim.

    (Refer to Body - "DOOR SCUFF TRIM ")

  20. Separate the accelerator pedal (A) after loosening the bolts.
    Fig 5: Locating Accelerator Pedal With Bolts
    G12145070Courtesy of KIA MOTORS AMERICA, INC.
  21. Separate the floor carpet (A) to allow space for removing the rear heating duct.

    [LH] 

    Fig 6: Locating Floor Carpet (LH)
    G12145071Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    Fig 7: Locating Floor Carpet (RH)
    G12145072Courtesy of KIA MOTORS AMERICA, INC.
  22. Remove the rear heating duct (A) after loosening the clip.

    [LH] 

    Fig 8: Locating Rear Heating Duct With Clip (LH)
    G12145073Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    Fig 9: Locating Rear Heating Duct With Clip (RH)
    G12145074Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the shift lever assembly.

    (Refer to Manual Transaxle System - "SHIFT LEVER ")

    (Refer to Automatic Transaxle System - "SHIFT LEVER ")

  24. Disconnect the airbag control module (SRSCM) connector (A).
    Fig 10: Locating Airbag Control Module Connector
    G12145075Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the passenger compartment junction box connectors (A).
    Fig 11: Locating Passenger Compartment Junction Box Connectors
    G12145076Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the multi box connectors (A).

    [LH] 

    Fig 12: Locating Multi Box Connectors (LH)
    G12145077Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    Fig 13: Locating Multi Box Connectors (RH)
    G12145078Courtesy of KIA MOTORS AMERICA, INC.
  27. Disconnect the connector (A) and the mounting clips in the front pillar.

    [LH] 

    Fig 14: Locating Front Pillar Connector (LH)
    G12145079Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    Fig 15: Locating Front Pillar Connector (RH)
    G12145080Courtesy of KIA MOTORS AMERICA, INC.
  28. Remove the drain hose (A).
    Fig 16: Locating Drain Hose
    G12145081Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the nuts and bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.

    [LH] 

    Fig 17: Locating Main Crash Pad And Cowl Cross Bar Assembly With Nuts And Bolts (LH)
    G12145082Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    Fig 18: Locating Main Crash Pad And Cowl Cross Bar Assembly With Nuts And Bolts (RH)
    G12145083Courtesy of KIA MOTORS AMERICA, INC.
  30. Disconnect the heater & blower unit connectors.
    1. Disconnect the evaporator temperature sensor (A), temperature control actuator (B) and FET(C) connectors, and then remove the wiring mounting clips.
      Fig 19: Locating Evaporator Temperature Sensor, Temperature Control Actuator And FET Connectors With Wiring Mounting Clips
      G12145084Courtesy of KIA MOTORS AMERICA, INC.
    2. Disconnect the blower motor connector (A).
      Fig 20: Locating Blower Motor Connector
      G12145085Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the intake actuator connector (A).
      Fig 21: Locating Intake Actuator Connector
      G12145086Courtesy of KIA MOTORS AMERICA, INC.
    4. Loosen the mounting screws from BCM unit and smart key unit.
      Fig 22: Locating BCM Unit And Smart Key Unit With Mounting Screws
      G12145087Courtesy of KIA MOTORS AMERICA, INC.
    5. Disconnect the aspirator hose (A).
      Fig 23: Locating Aspirator Hose
      G12145088Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the AFLS (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring mounting clips.
      Fig 24: Locating AFLS, Temperature Control Actuator With Mode Control Actuator Connectors With Wiring Mounting Clips
      G12145089Courtesy of KIA MOTORS AMERICA, INC.
    7. Disconnect the auto defogging actuator connector (A) and then remove the wiring mounting clips.
    Fig 25: Locating Auto Defogging Actuator Connector
    G12145090Courtesy of KIA MOTORS AMERICA, INC.
  31. Loosen the heater & blower unit mounting bolt (A).
    Fig 26: Locating Heater & Blower Unit Mounting Bolt
    G12145091Courtesy of KIA MOTORS AMERICA, INC.
  32. Remove the heater and blower unit (A) from the crash pad after loosening the mounting nuts.
    Fig 27: Locating Heater And Blower Unit With Mounting Nuts
    G12145092Courtesy of KIA MOTORS AMERICA, INC.
  33. Separate the blower unit (B) from the heater unit (A) after loosening the screws.
    Fig 28: Blower Unit And Heater Unit With Screws (1 Of 2)
    G12145093Courtesy of KIA MOTORS AMERICA, INC.
    Fig 29: Blower Unit And Heater Unit With Screws (2 Of 2)
    G12145094Courtesy of KIA MOTORS AMERICA, INC.
    Fig 30: Locating Blower Unit And Heater Unit
    G12145095Courtesy of KIA MOTORS AMERICA, INC.
  34. Install in the reverse order of removal.
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