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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2020 Kia Sorento. However, it is still accessible from the selected car via links, so may be relevant.
  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 ")

    NOTE: If Lambda engine, remove the surge tank.
    (Refer to Engine mechanical systems - "SURGE TANK ")
  5. 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 Ib-ft)

    G12885147Courtesy of KIA MOTORS AMERICA, INC.
  6. 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 Ib-ft)

    G12885148Courtesy of KIA MOTORS AMERICA, INC.
  7. Remove the expansion valve flange (A) after loosening the screws.
    G12885149Courtesy 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).
  8. Disconnect the heater hose (A).
    G12885150Courtesy of KIA MOTORS AMERICA, INC.
  9. Remove the inlet and outlet heater hoses flange (A) after loosening the nuts (B).
    G12885151Courtesy 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.
  10. Loosen the cowl cross member mounting bolts (A).
    G12885152Courtesy of KIA MOTORS AMERICA, INC.
  11. Remove both sides of front seat assembly.

    (Refer to Body - "FRONT SEAT ASSEMBLY ")

  12. Remove the floor console.

    (Refer to Body - "FLOOR CONSOLE ")

  13. Remove both sides of the front pillar trim.

    (Refer to Body - "FRONT PILLAR TRIM ")

  14. Remove both sides of the cowl side trim.

    (Refer to Body - "COWL SIDE TRIM ")

  15. Remove the crash pad lower panel.

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

  16. Remove the steering column shroud lower panel.

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

  17. Remove the steering wheel.

    (Refer to Steering System - "STEERING WHEEL ")

  18. Remove the multifunction switch.

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

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

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

  20. Remove the front door scuff trim.

    (Refer to Body - "DOOR SCUFF TRIM ")

  21. Separate the accel pedal (A) after removing the cap (B) and then loosening the nut and bolt.
    G12885153Courtesy of KIA MOTORS AMERICA, INC.
  22. Separate the floor carpet (A) to obtain space for removing the rear heating duct.

    [LH] 

    G12885154Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    G12885155Courtesy of KIA MOTORS AMERICA, INC.
  23. Remove the car mat (A).

    [LH] 

    G12885156Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    G12885157Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the rear heating duct (A) after loosening the bolts.

    [LH] 

    G12885158Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    G12885159Courtesy of KIA MOTORS AMERICA, INC.
  25. Remove the shift cable (A).
    G12885160Courtesy of KIA MOTORS AMERICA, INC.
    NOTE: Remove the cable after pushing the locking pin in the direction of the arrow.
    G12885161Courtesy of KIA MOTORS AMERICA, INC.
  26. Remove the shift lever assembly (A) after loosening the bolts.
    G12885162Courtesy of KIA MOTORS AMERICA, INC.
  27. Disconnect the airbag control module (SRSCM) connector (A).
    G12885163Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the passenger compartment junction box connectors (A).
    G12885164Courtesy of KIA MOTORS AMERICA, INC.
  29. Disconnect the multi box connectors (A).

    [Driver's] 

    G12885165Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G12885166Courtesy of KIA MOTORS AMERICA, INC.
  30. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    G12885167Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G12885168Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the drain hose (A).
    G12885169Courtesy of KIA MOTORS AMERICA, INC.
  32. After loosening the nuts and bolts remove the main crash pad and cowl cross bar assembly (A) together.

    [LH] 

    G12885170Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    G12885171Courtesy of KIA MOTORS AMERICA, INC.
  33. Disconnect the heater & blower unit connectors.
    1. Remove the smart key unit (A) after loosening the nut and screw.
      G12885172Courtesy of KIA MOTORS AMERICA, INC.
    2. Disconnect the temperature control actuator (A), mode control actuator (B) connectors and then remove the wiring mounting clips.
      G12885173Courtesy of KIA MOTORS AMERICA, INC.
    3. Disconnect the blower motor connector (A) and then remove the wiring mounting clips.
      G12885174Courtesy of KIA MOTORS AMERICA, INC.
    4. Disconnect the temperature control actuator (A), FET (B), evaporator temperature sensor (C) connectors and then remove the wiring mounting clips.
      G12885175Courtesy of KIA MOTORS AMERICA, INC.
    5. Disconnect the intake actuator (A), auto defogging actuator (B) connectors and then remove the wiring mounting clips.
      G12885176Courtesy of KIA MOTORS AMERICA, INC.
    6. Remove the aspirator hose (A) after loosening the screw.
    G12885177Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the heater and blower unit (A) from the crash pad after loosening the mounting nuts.
    G12885178Courtesy of KIA MOTORS AMERICA, INC.
  35. Separate the blower unit (B) from the heater unit (A) after loosening the screws.
    G12885179Courtesy of KIA MOTORS AMERICA, INC.
    G12885180Courtesy of KIA MOTORS AMERICA, INC.
    G12885181Courtesy of KIA MOTORS AMERICA, INC.
  36. Install in the reverse order of removal.
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