Hyundai Sonata: Heater / Evaporator Core Repair procedures

Replacement
1.
Disconnect the negative (-) battery terminal.
2.
After loosening the bolts remove the main crash pad and cowl cross bar assembly together.
(Refer to Heater -"Heater Unit")
3.
Remove the heater and blower assembly.
(Refer to Heater -"Heater Unit")
4.
Separate the blower unit (B) from the heater unit (A) after loosening the screws.

5.
Remove the heater unit lower case mounting clip (A).
6.
Remove the heater unit lower case (B) after loosening the mounting screws.

7.
Pull out the evaporator core (A) from the heater unit.

8.
Install in the reverse order of removal.
A.
If you're installing a new heater core, add refrigerant oil (PAG OIL).
B.
Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
C.
Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D.
Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately.
E.
Apply sealant to the grommets.
F.
Make sure that there is no air leakage.
G.
Charge the system and test its performance.
H.
Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
Heater Core Repair procedures
Replacement 1. Disconnect the negative (-) battery terminal. 2. After loosening the bolts remove the main crash pad and cowl cross bar assembly together. (Refer to Heater -"Heater Unit") ...

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