Hyundai Genesis: Heater / Heater Unit Repair procedures

Replacement

1.	Disconnect the negative (-) battery terminal.

2.	Recover the refrigerant with a recovery/recycling/charging station.

3.	When the engine cools down, 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.	Remove the bolts and the expansion valve (A) from the evaporator core. • Plug or cap the lines immediately after disconnecting them to avoid the intrusion of moisture and dust. • When installing, replace with a new O-ring.

6.	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.

7.	Loosen the cowl cross member mounting bolts.

8.	Remove the front seat assembly. (Refer to Body - "Front Seat Assembly")

9.	Remove the main crash pad. (Refer to Body -"Main Crash Pad")

10.	Disconnect the steering column connectors. (Refer to Steering System - "Steering Column and Shaft")

11.	Pull down the steering column after loosening the mounting bolts and through bolts. (Refer to Steering System - "Steering Column and Shaft")

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

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

14.	Disconnect the junction box connectors (A).

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

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

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

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

19.	After loosening the screws, remove the heater core cover (A).

20.	Pull out the heater core (A) from the heater unit.

21.	Loosen the heater lower case mounting screws.

22.	Remove the lower case (A).

23.	Pull out the evaporator core (A) from the heater unit. • Be careful that the inlet and outlet pipe are not bent during evaporator core removal/installation.

24.

Install in the reverse order of removal. • If you're installing a new evaporator core, add compressor oil (PAG OIL). • 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. • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption. • 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. • Apply sealant to the grommets. • Make sure that there is no air leakage. • Charge the system and test its performance. • Do not interchange the inlet and outlet heater hoses and tighten the hose clamps firmly. • Refill the cooling system with engine coolant.

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