Hyundai Sonata: Heater Unit Repair procedures - Heater - Heating, Ventilation and Air ConditioningHyundai Sonata: Heater Unit Repair procedures

Replacement
   
When prying with a flat-tip screwdriver or use a prying trim tool, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
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")
5.
After loosening the mounting nut, then remove the expansion valve cover (A).

Tightening torque :
8.8 ~ 11.7 N.m ( 0.9 ~ 1.2 kgf.m, 6.5 ~ 8.6 Ib-ft)

6.
Remove the bolts and the expansion valve (A) from the evaporator core.

Tightening torque :
8.8 ~ 11.7 N.m ( 0.9 ~ 1.2 kgf.m, 6.5 ~ 8.6 Ib-ft)

   
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
When installing, replace with a new O-ring.
7.
Disconnect the inlet (A) and outlet (B) heater hoses from the heater unit.

   
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.
8.
Loosen the cowl cross member mounting bolts.

9.
Remove both sides of front seat assembly.
(Refer to Body - "Front Seat Assembly")
10.
Remove the floor console assembly.
(Refer to Body - "Floor Console Assembly")
11.
Remove the crash pad lower panel.
(Refer to Body - "Crash Pad Lower Panel")
12.
Remove the crash pad side cover.
(Refer to Body - "Crash Pad Center Panel")
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 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 shift lever assembly.
(Refer to Automatic Transmission System - "Shift Lever")
20.
Disconnect the airbag control module (SRSCM) connector (A).

21.
Disconnect the junction box connectors (A).

22.
Disconnect the multi box connectors (A).
[Driver's side]

[Passenger's side]

23.
Disconnect the connectors (A) and the mounting clips in the front pillar.
[Driver's side]

[Passenger's side]

24.
Remove the drain hose (A).

25.
After loosening the bolts remove the main crash pad and cowl cross bar assembly (A) together.

26.
Disconnect the heater & blower unit connectors.
(1)
Disconnect the blower motor connector (A) and then remove the wiring mounting clips.

(2)
Disconnect the mode control actuator (A), temperature control actuator (B) connectors and then remove the wiring mounting clips.

(3)
Disconnect the Intake Actuator (A), field effect transistor (B) connectors and then remove the wiring mounting clips.

27.
Remove the center fascia panel.
(Refer to Body - "Center Fascia Panel")
28.
Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.

29.
Separate the blower unit (B) from the heater unit (A) after loosening the screws.

30.
Install in the reverse order of removal.
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