Kia Sportage: Air conditioning System / Evaporator Core Repair procedures

Kia Sportage QL (2015-2025) Service Manual / Heating,Ventilation And Air Conditioning / Air conditioning System / Evaporator Core Repair procedures

Replacement

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")

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

Tightening torque : 7.8 - 11.8 N.m ( 0.8 - 1.2 kgf.m, 5.8 - 8.7 Ib-ft)

Remove the expansion valve (A) from the evaporator core after loosening the bolts.

Tightening torque : 7.8 - 11.8 N.m ( 0.8 - 1.2 kgf.m, 5.8 - 8.7 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.	Remove the air cleaner assembly. (Refer to Engine Mechanical System - "Air Cleaner")

Disconnect the heater hoses (A).

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).

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 bolt and nut.

21.	Remove the rear duct (A). [LH] [RH]

22.	Separate the floor carpet (A) to allow space for removing the rear heating duct. [LH] [RH]

23.	Remove the rear heating duct (A) after loosening the nut. [LH] [RH]

24.	Remove the shift lever assembly. (Refer to Manual Transaxle System - "Shift Lever") (Refer to Automatic Transaxle System - "Shift Lever")

25.	Disconnect the airbag control module (SRSCM) connector (A).

26.	Disconnect the passenger compartment junction box connectors (A).

27.	Disconnect the multi box connectors (A). [LH] [RH]

28.	Disconnect the connector (A) and the mounting clips in the front pillar. [LH] [RH]

29.	Remove the drain hose (A).

30.	After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether. [LH] [RH]

31.	Remove the Evaporator temperature sensor. (Refer to Air Conditioning System - "Evaporator Temperature Sensor")

32.	Remove the heater unit lower case (A) after loosening the mounting screws.

33.	Remove the evaporator core (A) from the heater unit.

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