Kia Optima Hybrid: Heater / Heater Unit Repair procedures

Replacement
1.
Disconnect the negative (-) battery terminal.
2.
Recover the refrigerant with a recovery/ recycling/ charging station.
   
1)
Do not use the same A/C recovery / charging station as conventional belt-driven compressors.
2)
Since the electric compressor uses high-voltage, you should use PVE or POE oil which have high Volumetric Resistivity.
3)
If the PVE or POE oil of the system gets mixed with PAG oil, then dielectric breakdown due to decreased volumetric Resistivity can occur and inoperative A/C compressor may result, A/C compressor may not work.
3.
When the engine is cool, drain the engine coolant from the radiator.
4.
Remove the expansion valve cover (A).

5.
Remove the bolts (A) and the expansion valve (B) from the evaporator core.

Tightening torque :
7.8 ~ 11.7 N.m ( 0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 Ib-ft)

   
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
6.
Disconnect the inlet (C) and outlet (D) 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.
Remove the center console.
(Refer to BD group - “Center Console”)
8.
Remove the shift lever housing assembly.
(Refer to TR grou - “Shift Lever”)
9.
Remove the steering handle and column.
(Refer to ST group - “Steering Column”)
10.
Loosen the cowl cross member mounting bolts (A).

11.
Remove the front pillar trim and then disconnect the connector (A).

12.
Disconnect the air bag connector (A).

13.
Remove the cowl side trim and then disconnect the connectors (A).

14.
Disconnect the fuse box connector (B).

15.
Loosen the heater & blower unit mounting bolts.

16.
Loosen the cowl cross member mounting bolts (A) and then remove the crash pad and heater blower unit (B).

17.
Disconnect the connectors and then remove the heater blower unit (A) from crash pad.

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

19.
Loosen the mounting screw and then remove the heater core cover (A).

20.
Disconnect the heater core (A) from heater unit.

21.
Loosen the mounting screws and then remove the heater unit lower case (A).

22.
Remove the evaporator core (A).

23.
Installation is the reverse order of removal.25. Installation is the reverse order of removal, and note these items :
If you''re installing a new evaporator, add refrigerant oil. (PVE or POE 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 install the hose clamps securely.
Refill the cooling system with engine coolant
Heater Unit Components and Components Location

Component Location Components 1. Heater Case (LH)2. Separator3. Evaporator Core4. Shower Duct5. Heater Core Cover6. Heater Core7. Mode Actuator8. Mode Cam9. Temp Actuator10. Vent Door Arm11. Floor Door ...

Temperature Control Actuator Components and Components Location

Component Location ...

Other information:

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