Hyundai Car 1999-05

Removal & Installation 2

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Sonata



Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Remove the heater hoses from the heater housing.
  6.  
  7. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. Remove the suction and discharge hoses from the evaporator assembly. Cap the hoses to minimize contamination.
  10.  
  11. Remove the evaporator drain hose.
  12.  
  13. Remove the SRS module and the steering wheel by removing or disconnecting the following:
    CAUTION
    Store the SRS module in a safe place with the front facing upward.



    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     



    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column

    Click image to see an enlarged view

    Fig. Instrument panel assembly-Sonata



    Click image to see an enlarged view

    Fig. Instrument panel screw locations-Sonata

     

  14.  
  15. Remove or disconnect the following:

    Front and rear console assembly and remove both side covers
     
    Glove box, the center pad cover, the center crash pad and the cassette assembly
     
    Lower crash pad. Remove the console mounting bracket and the center support bracket
     
    Rear heater ducts from the heater housing
     
    Control assembly
     
    Blower speed control actuator connector and the blend door actuator connector, if equipped with semi-automatic temperature control
     
    4 retaining bolts and remove the heater assembly
     

  16.  
  17. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the heater housing assembly-Sonata

     

  18.  

To install:

  1. Install or connect the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater assembly and attach it to the dash panel with the mounting bolts
     
    Heater control assembly. Connect the ducts to the heater housing
     
    Console mounting bracket and the center support bracket
     
    Lower crash pad and both side covers
     
    Front and rear console assembly
     

  2.  
  3. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     
    Evaporator tubes, the heater hoses and the drain hose
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Evacuate, charge and leak test the air conditioning system.
  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

Sonata And Xg 350



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the heater hoses from the heater housing.
  8.  
  9. Discharge and recover the air conditioning system refrigerant.
  10.  
  11. Remove the suction and discharge hoses from the evaporator assembly. Cap the hoses to minimize contamination.
  12.  
  13. Remove the evaporator drain hose.
  14.  
  15. Remove the SRS module and the steering wheel by removing or disconnecting the following:
    CAUTION
    Store the SRS module in a safe place with the front facing upward.



    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     



    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column

    Click image to see an enlarged view

    Fig. Instrument panel assembly-Sonata



    Click image to see an enlarged view

    Fig. Instrument panel screw locations-Sonata

     

  16.  
  17. Remove or disconnect the following:

    Front and rear console assembly and remove both side covers
     
    Glove box, the center pad cover, the center crash pad and the cassette assembly
     
    Lower crash pad. Remove the console mounting bracket and the center support bracket
     
    Rear heater ducts from the heater housing
     
    Control assembly
     
    Blower speed control actuator connector and the blend door actuator connector, if equipped with semi-automatic temperature control
     
    4 retaining bolts and remove the heater assembly
     

  18.  
  19. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the heater housing assembly-Sonata

     

  20.  

To install:

  1. Install or connect the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater assembly and attach it to the dash panel with the mounting bolts
     
    Heater control assembly. Connect the ducts to the heater housing
     
    Console mounting bracket and the center support bracket
     
    Lower crash pad and both side covers
     
    Front and rear console assembly
     

  2.  
  3. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     
    Evaporator tubes, the heater hoses and the drain hose
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Evacuate, charge and leak test the air conditioning system.
  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

Sonata, Xg 300 And Xg 350



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Remove the heater hoses from the heater housing.
  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Remove the suction and discharge hoses from the evaporator assembly. Cap the hoses to minimize contamination.
  8.  
  9. Remove the evaporator drain hose.
  10.  
  11. Remove the SRS module and the steering wheel by removing or disconnecting the following:

    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     

  12.  


CAUTION
Store the SRS module in a safe place with the front facing upward.



Steering wheel-to-steering column nut
 
Steering wheel from the steering column
 



Click image to see an enlarged view

Fig. Instrument panel assembly-Sonata



Click image to see an enlarged view

Fig. Instrument panel screw locations-Sonata

  1. Remove or disconnect the following:

    Front and rear console assembly and remove both side covers
     
    Glove box, the center pad cover, the center crash pad and the cassette assembly
     
    Lower crash pad. Remove the console mounting bracket and the center support bracket
     
    Rear heater ducts from the heater housing
     
    Control assembly
     
    Blower speed control actuator connector and the blend door actuator connector, if equipped with semi-automatic temperature control
     
    4 retaining bolts and remove the heater assembly
     

  2.  
  3. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the heater housing assembly-Sonata


To install:

  1. Install or connect the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater assembly and attach it to the dash panel with the mounting bolts
     
    Heater control assembly. Connect the ducts to the heater housing
     
    Console mounting bracket and the center support bracket
     
    Lower crash pad and both side covers
     
    Front and rear console assembly
     

  2.  
  3. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     
    Evaporator tubes, the heater hoses and the drain hose
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Evacuate, charge and leak test the air conditioning system.
  10.  
  11. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  12.  

Tiburon



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  1. Discharge and recover the air conditioning system refrigerant.
  2.  
  3. Drain the engine coolant into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core. Plug the openings.
  6.  
  7. Disconnect the vacuum line from the heater housing vacuum nipple.
  8.  
  9. Remove the SRS module and the steering wheel by removing or disconnecting the following:

    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column
     

  10.  
  11. Remove the instrument panel by removing or disconnecting the following:

    Upper console cover
     
    Center fascia panel and disconnect the cigar lighter connector
     
    3 lower instrument panel screws and the lower instrument panel
     
    Radio-to-bracket bolts and the radio
     
    Rheostat switch, the hood release handle and DLC from the lower instrument panel
     
    5 cluster fascia panel-to-instrument panel screws; then, disconnect the heater control cable and the cluster electrical connectors and remove the cluster fascia panel
     
    4 instrument cluster-to-instrument panel screws and the instrument cluster
     
    2 glove box-to-instrument panel bolts and the glove box
     
    4 upper glove box cover-to-instrument panel screws, the 2 glove box striker screws and the upper glove box cover
     
    Upper instrument panel speaker grille
     
    2 upper speaker-to-instrument panel screws
     
    Instrument panel-to-chassis bolts, disconnect the electrical connectors and remove the instrument panel
     

  12.  
  13. Remove or disconnect the following:

    Front right side heating duct from the heater housing
     
    Pull back the carpet and remove the right side console mounting bracket
     
    Front left side duct from the heater housing
     
    Pull back the carpet and remove the left side console mounting bracket
     
    Rear heating duct from the heater housing
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Center fascia panel support bracket screws, bolts and/or nuts; then, remove the center fascia panel support bracket
     
    Center support bars
     
    Glove box support bracket-to-instrument panel bolts and the bracket
     

  14.  
  15. Remove the evaporator housing by removing or disconnecting the following:

    Refrigerant lines (located in the engine compartment), from the evaporator housing and discard the O-rings
     
    Thermostatic switch connector
     
    Evaporator housing upper and lower bolts
     
    Evaporator housing
     
    Heater housing-to-chassis bolts and the housing
     

  16.  
  17. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core
     

  18.  


    Click image to see an enlarged view

    Fig. Exploded view of the SRS module, steering wheel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Coupe



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Sedan and Wagon



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing and related components-Tiburon


To install:

  1. Assemble the heater housing by installing or connecting the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater housing and the housing-to-chassis bolts
     

  2.  
  3. Install the evaporator housing by installing or connecting the following:

    Evaporator housing
     
    Evaporator housing upper and lower bolts
     
    Thermostatic switch connector
     
    Connect the refrigerant lines to the evaporator housing using new O-rings
     

  4.  
  5. Install or connect the following:

    Glove box support bracket and the bracket-to-instrument panel bolts
     
    Center support bars
     
    Center fascia panel support bracket; then, install the center fascia panel support bracket screws, bolts and/or nuts
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Rear heating duct to the heater housing
     
    Left side console mounting bracket and install the carpet
     
    Front left side duct to the heater housing
     
    Right side console mounting bracket and install the carpet
     
    Front right side heating duct to the heater housing
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Instrument panel, connect the electrical connectors and install the instrument panel-to-chassis bolts
     
    2 upper speaker-to-instrument panel screws
     
    Upper instrument panel speaker grille
     
    Upper glove box cover, the 2 glove box striker screws and the 4 upper glove box cover-to-instrument panel screws
     
    Glove box and the 2 glove box-to-instrument panel bolts
     
    Instrument cluster and the 4 instrument cluster-to-instrument panel screws
     
    Cluster fascia panel; then, connect the heater control cable and the cluster electrical connectors and install the 5 cluster fascia panel-to-instrument panel screws
     
    Rheostat switch, the hood release handle and DLC to the lower instrument panel
     
    Radio and the radio-to-bracket bolts
     
    Lower instrument panel and the 3 lower instrument panel screws
     
    Cigar lighter connector and install the center fascia panel
     
    Upper console cover
     

  8.  
  9. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     

  10.  
  11. Install or connect the following:

    Vacuum line to the heater housing vacuum nipple
     
    Heater hoses to the heater core
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Evacuate, charge and leak test the air conditioning system.
  18.  
  19. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  4.  
  5. Discharge and recover the air conditioning system refrigerant.
  6.  
  7. Drain the engine coolant into a clean container for reuse.
  8.  
  9. Disconnect the heater hoses from the heater core. Plug the openings.
  10.  
  11. Disconnect the vacuum line from the heater housing vacuum nipple.
  12.  
  13. Remove the SRS module and the steering wheel by removing or disconnecting the following:

    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column
     

  14.  
  15. Remove the instrument panel by removing or disconnecting the following:

    Upper console cover
     
    Center fascia panel and disconnect the cigar lighter connector
     
    3 lower instrument panel screws and the lower instrument panel
     
    Radio-to-bracket bolts and the radio
     
    Rheostat switch, the hood release handle and DLC from the lower instrument panel
     
    5 cluster fascia panel-to-instrument panel screws; then, disconnect the heater control cable and the cluster electrical connectors and remove the cluster fascia panel
     
    4 instrument cluster-to-instrument panel screws and the instrument cluster
     
    2 glove box-to-instrument panel bolts and the glove box
     
    4 upper glove box cover-to-instrument panel screws, the 2 glove box striker screws and the upper glove box cover
     
    Upper instrument panel speaker grille
     
    2 upper speaker-to-instrument panel screws
     
    Instrument panel-to-chassis bolts, disconnect the electrical connectors and remove the instrument panel
     

  16.  
  17. Remove or disconnect the following:

    Front right side heating duct from the heater housing
     
    Pull back the carpet and remove the right side console mounting bracket
     
    Front left side duct from the heater housing
     
    Pull back the carpet and remove the left side console mounting bracket
     
    Rear heating duct from the heater housing
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Center fascia panel support bracket screws, bolts and/or nuts; then, remove the center fascia panel support bracket
     
    Center support bars
     
    Glove box support bracket-to-instrument panel bolts and the bracket
     

  18.  
  19. Remove the evaporator housing by removing or disconnecting the following:

    Refrigerant lines (located in the engine compartment), from the evaporator housing and discard the O-rings
     
    Thermostatic switch connector
     
    Evaporator housing upper and lower bolts
     
    Evaporator housing
     
    Heater housing-to-chassis bolts and the housing
     

  20.  
  21. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the SRS module, steering wheel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Coupe



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Sedan and Wagon



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing and related components-Tiburon

     

  22.  

To install:

  1. Assemble the heater housing by installing or connecting the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater housing and the housing-to-chassis bolts
     

  2.  
  3. Install the evaporator housing by installing or connecting the following:

    Evaporator housing
     
    Evaporator housing upper and lower bolts
     
    Thermostatic switch connector
     
    Connect the refrigerant lines to the evaporator housing using new O-rings
     

  4.  
  5. Install or connect the following:

    Glove box support bracket and the bracket-to-instrument panel bolts
     
    Center support bars
     
    Center fascia panel support bracket; then, install the center fascia panel support bracket screws, bolts and/or nuts
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Rear heating duct to the heater housing
     
    Left side console mounting bracket and install the carpet
     
    Front left side duct to the heater housing
     
    Right side console mounting bracket and install the carpet
     
    Front right side heating duct to the heater housing
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Instrument panel, connect the electrical connectors and install the instrument panel-to-chassis bolts
     
    2 upper speaker-to-instrument panel screws
     
    Upper instrument panel speaker grille
     
    Upper glove box cover, the 2 glove box striker screws and the 4 upper glove box cover-to-instrument panel screws
     
    Glove box and the 2 glove box-to-instrument panel bolts
     
    Instrument cluster and the 4 instrument cluster-to-instrument panel screws
     
    Cluster fascia panel; then, connect the heater control cable and the cluster electrical connectors and install the 5 cluster fascia panel-to-instrument panel screws
     
    Rheostat switch, the hood release handle and DLC to the lower instrument panel
     
    Radio and the radio-to-bracket bolts
     
    Lower instrument panel and the 3 lower instrument panel screws
     
    Cigar lighter connector and install the center fascia panel
     
    Upper console cover
     

  8.  
  9. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     

  10.  
  11. Install or connect the following:

    Vacuum line to the heater housing vacuum nipple
     
    Heater hoses to the heater core
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Evacuate, charge and leak test the air conditioning system.
  18.  
  19. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 30 seconds for the SRS module to deplete its stored energy.

  2.  
  3. Discharge and recover the air conditioning system refrigerant.
  4.  
  5. Drain the engine coolant into a clean container for reuse.
  6.  
  7. Disconnect the heater hoses from the heater core. Plug the openings.
  8.  
  9. Disconnect the vacuum line from the heater housing vacuum nipple.
  10.  
  11. Remove the SRS module and the steering wheel by removing or disconnecting the following:

    Steering wheel-to-SRS module nuts
     
    SRS module from the steering wheel and disconnect the electrical connector
     
    Steering wheel-to-steering column nut
     
    Steering wheel from the steering column
     

  12.  
  13. Remove the instrument panel by removing or disconnecting the following:

    Upper console cover
     
    Center fascia panel and disconnect the cigar lighter connector
     
    3 lower instrument panel screws and the lower instrument panel
     
    Radio-to-bracket bolts and the radio
     
    Rheostat switch, the hood release handle and DLC from the lower instrument panel
     
    5 cluster fascia panel-to-instrument panel screws; then, disconnect the heater control cable and the cluster electrical connectors and remove the cluster fascia panel
     
    4 instrument cluster-to-instrument panel screws and the instrument cluster
     
    2 glove box-to-instrument panel bolts and the glove box
     
    4 upper glove box cover-to-instrument panel screws, the 2 glove box striker screws and the upper glove box cover
     
    Upper instrument panel speaker grille
     
    2 upper speaker-to-instrument panel screws
     
    Instrument panel-to-chassis bolts, disconnect the electrical connectors and remove the instrument panel
     

  14.  
  15. Remove or disconnect the following:

    Front right side heating duct from the heater housing
     
    Pull back the carpet and remove the right side console mounting bracket
     
    Front left side duct from the heater housing
     
    Pull back the carpet and remove the left side console mounting bracket
     
    Rear heating duct from the heater housing
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Center fascia panel support bracket screws, bolts and/or nuts; then, remove the center fascia panel support bracket
     
    Center support bars
     
    Glove box support bracket-to-instrument panel bolts and the bracket
     

  16.  
  17. Remove the evaporator housing by removing or disconnecting the following:

    Refrigerant lines (located in the engine compartment), from the evaporator housing and discard the O-rings
     
    Thermostatic switch connector
     
    Evaporator housing upper and lower bolts
     
    Evaporator housing
     
    Heater housing-to-chassis bolts and the housing
     

  18.  
  19. Disassemble the heater housing by removing or disconnecting the following:

    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Vacuum motor rod end connection and remove the vacuum motors
     
    Heater housing cover clips
     
    Cover and the heater core

    Click image to see an enlarged view

    Fig. Exploded view of the SRS module, steering wheel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Tiburon



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Coupe



    Click image to see an enlarged view

    Fig. Exploded view of the heater housing, center fascia, distribution ducts and related components-Tiburon Sedan and Wagon



    Click image to see an enlarged view

    Fig. Exploded view of the heater core and heater housing and related components-Tiburon

     

  20.  

To install:

  1. Assemble the heater housing by installing or connecting the following:

    Heater core and the cover
     
    Heater housing cover clips
     
    Vacuum motor rod end connection and install the vacuum motors
     
    Vacuum motor-to-heater housing bolts (2 for each vacuum motor)
     
    Heater housing and the housing-to-chassis bolts
     

  2.  
  3. Install the evaporator housing by installing or connecting the following:

    Evaporator housing
     
    Evaporator housing upper and lower bolts
     
    Thermostatic switch connector
     
    Connect the refrigerant lines to the evaporator housing using new O-rings
     

  4.  
  5. Install or connect the following:

    Glove box support bracket and the bracket-to-instrument panel bolts
     
    Center support bars
     
    Center fascia panel support bracket; then, install the center fascia panel support bracket screws, bolts and/or nuts
     
    Control modules electrical connectors at the center fascia panel support bracket
     
    Rear heating duct to the heater housing
     
    Left side console mounting bracket and install the carpet
     
    Front left side duct to the heater housing
     
    Right side console mounting bracket and install the carpet
     
    Front right side heating duct to the heater housing
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Instrument panel, connect the electrical connectors and install the instrument panel-to-chassis bolts
     
    2 upper speaker-to-instrument panel screws
     
    Upper instrument panel speaker grille
     
    Upper glove box cover, the 2 glove box striker screws and the 4 upper glove box cover-to-instrument panel screws
     
    Glove box and the 2 glove box-to-instrument panel bolts
     
    Instrument cluster and the 4 instrument cluster-to-instrument panel screws
     
    Cluster fascia panel; then, connect the heater control cable and the cluster electrical connectors and install the 5 cluster fascia panel-to-instrument panel screws
     
    Rheostat switch, the hood release handle and DLC to the lower instrument panel
     
    Radio and the radio-to-bracket bolts
     
    Lower instrument panel and the 3 lower instrument panel screws
     
    Cigar lighter connector and install the center fascia panel
     
    Upper console cover
     

  8.  
  9. Install the SRS module and the steering wheel by installing or connecting the following:

    Steering wheel to the steering column
     
    Steering wheel-to-steering column nut and torque to 30-37 ft. lbs. (40-50 Nm)
     
    SRS module to the steering wheel and connect the electrical connector
     
    Steering wheel-to-SRS module nuts
     

  10.  
  11. Install or connect the following:

    Vacuum line to the heater housing vacuum nipple
     
    Heater hoses to the heater core
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Evacuate, charge and leak test the air conditioning system.
  18.  
  19. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  20.  

 
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