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 ) or (Refer to ENGINE COOLING SYSTEM - 2.0L )
Remove the cowl top cover.
(Refer to COWL TOP COVER )
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 1: Expansion Valve
Courtesy of KIA MOTORS AMERICA, INC.
Remove the expansion valve flange (A) after loosening the screws.

Fig 2: Expansion Valve Flange With 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 inlet (A) and outlet (B) heater hoses from the heater unit.

Fig 3: Inlet & Outlet Heater Hoses
Courtesy of KIA MOTORS AMERICA, INC.
CAUTION:
- When disconnecting the hoses, engine coolant will pour out of the hose. So drain the coolant into a clean drip pan.
Remove the inlet and outlet heater hoses flange (A) after loosening the nuts (B).

Fig 4: Inlet & Outlet Heater Hoses Flange With Mounting Nuts
Courtesy of KIA MOTORS AMERICA, INC.

Fig 5: Inlet & Outlet Heater Hoses Flange
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the cowl cross member mounting bolts (A).

Fig 6: Cowl Cross Member Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove both sides of front seat assembly.
(Refer to "FRONT SEAT ASSEMBLY ")
Remove the floor console assembly.
(Refer to "FLOOR CONSOLE ASSEMBLY ")
Remove the center fascia panel.
(Refer to "CENTER FASCIA PANEL ")
Remove the crash pad lower panel.
(Refer to "CRASH PAD LOWER PANEL ")
Remove the glove box housing.
(Refer to "GLOVE BOX HOUSING ")
Remove the crash pad center lower panel.
(Refer to "CRASH PAD CENTER PANEL ")
Remove both sides of the front pillar trim.
(Refer to "FRONT PILLAR TRIM ")
Remove both sides of the cowl side trim.
(Refer to "COWL SIDE TRIM ")
Remove the steering column shroud lower panel.
(Refer to "STEERING COLUMN SHROUD PANEL ")
Remove the steering wheel.
(Refer to STEERING WHEEL )
Remove the multifunction switch.
(Refer to MULTIFUNCTION SWITCH )
Lower the steering column after loosening the mounting bolts.
(Refer to "STEERING COLUMN AND SHAFT ")
Remove the rear air duct assembly (A).

Fig 7: Removing Rear Air Duct Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Remove the shift lever assembly.
(Refer to SHIFT LEVER 1.6L ) or (Refer to SHIFT LEVER 2.0L )
Disconnect the airbag control module (SRSCM) connector (A).

Fig 8: Airbag Control Module Connector
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the mounting bolts and nuts, then remove the cowl cross bar center bracket (A).

Fig 9: Cowl Cross Bar Center Bracket
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the passenger compartment junction box connectors (A).

Fig 10: Passenger Compartment Junction Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Remove the passenger compartment junction box mounting clips (A).

Fig 11: Passenger Compartment Junction Box Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the multi box connectors (A).
[Driver's]

Fig 12: Driver Multi Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 13: Passenger Multi Box Connectors
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the connector (A) and the mounting clips (B) in the front pillar.
[Driver's]

Fig 14: Front Pillar Connector And Mounting Clips (Driver Side)
Courtesy of KIA MOTORS AMERICA, INC.

[Passenger's]

Fig 15: Front Pillar Connector And Mounting Clips (Passenger Side)
Courtesy of KIA MOTORS AMERICA, INC.
Remove the drain hose (A).

Fig 16: Drain Hose
Courtesy of KIA MOTORS AMERICA, INC.
After loosening the bolts remove the main crash pad and cowl cross bar assembly (A) together.

Fig 17: Main Crash Pad And Cowl Cross Bar Assembly
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the heater & blower unit connectors.
1. Disconnect the Intake actuator connector (A) and then remove the wiring mounting clips.
  
  Fig 18: Intake Actuator Connector
  Courtesy of KIA MOTORS AMERICA, INC.
2. Disconnect the blower motor (A), temperature control actuator (B), mode control actuator (C) connectors and then remove the wiring mounting clips.
  
  Fig 19: Blower Motor, Temperature Control Actuator And Mode Control Actuator Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
3. Disconnect the evaporator temperature sensor (A) field effect transistor air conditioning resistor (B) connectors and then remove the wiring mounting clips.
  
  Fig 20: Evaporator Temperature Sensor And Field Effect Transistor Air Conditioning Resistor Connectors
  Courtesy of KIA MOTORS AMERICA, INC.
4. Disconnect the cluster ionizer connector (A) and then remove the wiring mounting clips.
  
  Fig 21: Cluster Ionizer Connector
  Courtesy of KIA MOTORS AMERICA, INC.
5. Remove the heater & blower unit wiring mounting clips (A).
  
  Fig 22: Heater & Blower Unit Wiring Mounting Clips
  Courtesy of KIA MOTORS AMERICA, INC.
Remove the mounting clips (A).

Fig 23: Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.

Fig 24: Mounting Clip
Courtesy of KIA MOTORS AMERICA, INC.
Loosen the heater and blower unit mounting bolts (A)

Fig 25: Heater And Blower Unit Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.

Fig 26: Heater & Blower Unit And Crash Pad Nuts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the heater unit mounting clips (A).
Separate the blower unit (B) from the heater unit (C) after loosening the screws (D).

Fig 27: Blower Unit, Heater Unit And Heater Unit Mounting Clips
Courtesy of KIA MOTORS AMERICA, INC.
Install in the reverse order of removal.