Repair Procedures: Replacement

WARNING: This page is about a different car, the 2016 Kia Sedona. However, it is still accessible from the selected car via links, so may be relevant.

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 Mechanical System - "COOLANT ")
Remove the cowl top cover.
(Refer to Body - "COWL TOP COVER ")
Remove the Surge Tank.
(Refer to Engine Mechanical System - "SURGE TANK ")
Remove the expansion valve cover (A) after loosening the nut.
Tightening Torque: 6.9 ~ 10.8 N.m (0.7 ~ 1.1 kgf.m, 5.1 ~ 8.0 lb-ft)

Fig 1: Removing Expansion Valve Cover Nut
Courtesy of KIA MOTORS AMERICA, INC.
Remove the bolts and the expansion valve (A) 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 2: Removing Bolts And Expansion Valve From Evaporator Core
Courtesy of KIA MOTORS AMERICA, INC.
Remove the expansion valve flange (A) after loosening the screws.

Fig 3: Removing Expansion Valve Flange Screws
Courtesy 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).
Disconnect the air breather hose (A).

Fig 4: Locating Air Breather Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the intake hose (A) after loosening the clips.

Fig 5: Locating Intake Hose Clips
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater hose (A).

Fig 6: Locating Heater Hose
Courtesy of KIA MOTORS AMERICA, INC.
Remove the inlet and outlet heater hoses flange (A) after loosening the nuts (B).

Fig 7: Removing Inlet And Outlet Heater Hoses Flange
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.
Loosen the cowl cross member mounting bolts (A).

Fig 8: Loosening Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove both sides of front seat assembly.
(Refer to Body - "FRONT SEAT ASSEMBLY ")
Remove the floor console.
(Refer to Body - "FLOOR CONSOLE ")
Remove both sides of the front pillar trim.
(Refer to Body - "FRONT PILLAR TRIM ")
Remove both sides of the cowl side trim.
(Refer to Body - "COWL SIDE TRIM ")
Remove the crash pad center lower panel.
(Refer to Body - "CRASH PAD CENTER PANEL ")
Remove the steering column shroud lower panel.
(Refer to Body - "STEERING COLUMN SHROUD PANEL ")
Remove the steering wheel.
(Refer to Steering System - "STEERING WHEEL ")
Remove the multifunction switch.
(Refer to Body Electrical System - "MULTIFUNCTION SWITCH ")
Lower the steering column after loosening the mounting bolts.
(Refer to Steering System - "STEERING COLUMN AND SHAFT ")
Remove the front door scuff trim.
(Refer to Body - "DOOR SCUFF TRIM ")
Remove the rear duct cover (A) after loosening the screws.

Fig 9: Removing Rear Duct Cover Screws
Courtesy of KIA MOTORS AMERICA, INC.
Separate the radiator assembly (A) to obtain space for removing the air guard.
[Driver's]

Fig 10: Separating Radiator Assembly (Driver)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 11: Separating Radiator Assembly (Passenger)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the rear air duct (A) after detaching the clips.
[Driver's]

Fig 12: Removing Rear Air Duct (Driver)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 13: Removing Rear Air Duct (Passenger)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the select cable (A).

Fig 14: Removing Select Cable
Courtesy of KIA MOTORS AMERICA, INC.

NOTE: Remove the cable after pushing the locking pin in the direction of the arrow.

Fig 15: Pushing Locking Pin
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift lever assembly (A) after loosening the bolts.

Fig 16: Removing Shift Lever Assembly Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the airbag control module (SRSCM) connector (A).

Fig 17: Locating Airbag Control Module (SRSCM) Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the passenger compartment junction box connectors (A).

Fig 18: Locating Passenger Compartment Junction Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the multi box connectors (A).
[Driver's]

Fig 19: Locating Multi Box Connectors (Driver)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 20: Locating Multi Box Connectors (Passenger)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]

Fig 21: Disconnecting Connector And Mounting Clips (Driver)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 22: Disconnecting Connector And Mounting Clips (Passenger)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drain hose (A).

Fig 23: Removing Drain Hose
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the nuts and bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
[LH]

Fig 24: Removing Main Crash Pad And Cowl Cross Bar Assembly (LH)
Courtesy of KIA MOTORS AMERICA, INC.

[RH]

Fig 25: Removing Main Crash Pad And Cowl Cross Bar Assembly (RH)
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater & blower unit connectors.
1. Remove the BCM unit (A) after loosening the nuts.
  
  Fig 26: Removing BCM Unit Nuts
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the blower motor connector (A) and then remove the wiring mounting clip (B).
  
  Fig 27: Removing Wiring Mounting Clip
  Courtesy of KIA MOTORS AMERICA, INC.
3. Detach the photo sensor mounting clips (A).
  
  Fig 28: Detaching Photo Sensor Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
4. Remove the smart key unit (A) after loosening the bolt.
  
  Fig 29: Removing Smart Key Unit
  Courtesy of KIA MOTORS AMERICA, INC.
5. Disconnect the temperature control actuator (A) and mode control actuator (B) connectors, and then remove the wiring mounting clips.
  
  Fig 30: Disconnecting Temperature Control Actuator And Mode Control Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
6. Disconnect the evaporator temperature sensor (A), FET (B) and Temperature actuator (C) connectors and then remove the wiring mounting clips.
  
  Fig 31: Disconnecting Evaporator Temperature Sensor, FET And Temperature Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
7. Disconnect the intake actuator (A), cluster ionizer (B) and Auto defogging actuator (C) connectors and then remove the wiring mounting clips.
  
  Fig 32: Disconnecting Intake Actuator, Cluster Ionizer And Auto Defogging Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
8. Detach the main connector mounting clip (A).
Fig 33: Detaching Main Connector Mounting Clip
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the heater & blower unit mounting bolts (A).

Fig 34: Loosening Heater And Blower Unit Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater and blower unit (A) from the crash pad after loosening the mounting nuts.

Fig 35: Removing Heater And Blower Unit From Crash Pad
Courtesy of KIA MOTORS AMERICA, INC.
Separate the blower unit (B) from the heater unit (A) after loosening the screws.

Fig 36: Separating Blower Unit From Heater Unit
Courtesy of KIA MOTORS AMERICA, INC.

Fig 37: Loosening Blower Unit And Heater Unit Screws
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.