Hyundai Coupes/Sedans 1994-1998 Repair Guide

Heater Core

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REMOVAL & INSTALLATION



See Figure 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: The heater unit is located under the center of the dash, attached to the evaporator unit and blower unit

The heater core on all vehicles is contained inside the heater unit. The heater unit must be fully removed from the vehicle and then disassembled to gain access to the heater core. The following procedures outline removal, disassembly, assembly and installation of the heater unit.

Accent


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Fig. Fig. 2: Exploded view of the heater unit-Accent

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses and the evaporator drain hose.
  6.  
  7. Remove the vacuum hose from the heater unit.
  8.  
  9. Discharge and properly recycle the refrigerant from the air conditioning system.
  10.  
  11. Remove the suction and liquid tubes.
  12.  
  13. Remove the steering wheel and multifunction switch assembly.
  14.  
  15. Remove the console.
  16.  
  17. Remove the lower crash pad.
  18.  
  19. Remove the center facia panel.
  20.  
  21. Disconnect the electrical harness and vacuum lines from the heater control assembly.
  22.  
  23. Remove the heater control assembly.
  24.  
  25. Remove the radio.
  26.  
  27. Remove the glove box.
  28.  
  29. Remove the mounting bolts from the passenger airbag mounting bracket.
  30.  
  31. Remove the main crash pad assembly.
  32.  
  33. Disconnect the cables from the heater unit and the thermostatic switch connector from the evaporator unit.
  34.  
  35. Remove the main dash pad assembly.
  36.  
  37. Properly discharge and recycle the refrigerant in the air conditioning system.
  38.  
  39. Remove the evaporator unit.
  40.  
  41. Remove the heater unit.
  42.  
  43. Separate the case halves and remove the heater core.
  44.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the evaporator unit.
  6.  
  7. Properly evacuate, charge and leak test the air conditioning system.
  8.  
  9. Install the main dash pad assembly.
  10.  
  11. Connect the cables from the heater unit and the thermostatic switch connector from the evaporator unit.
  12.  
  13. Install the main crash pad assembly.
  14.  
  15. Install the mounting bolts from the passenger airbag mounting bracket.
  16.  
  17. Install the glove box.
  18.  
  19. Install the radio.
  20.  
  21. Install the heater control assembly.
  22.  
  23. Connect the electrical harness and vacuum lines to the heater control assembly.
  24.  
  25. Install the center facia panel.
  26.  
  27. Install the lower crash pad.
  28.  
  29. Install the console.
  30.  
  31. Install the steering wheel and multifunction switch assembly.
  32.  
  33. Install the suction and liquid tubes.
  34.  
  35. Discharge and properly recycle the refrigerant from the air conditioning system.
  36.  
  37. Install the vacuum hose from the heater unit.
  38.  
  39. Connect the heater hoses and the evaporator drain hose.
  40.  
  41. Fill the cooling system.
  42.  
  43. Connect the negative battery cable.
  44.  
  45. Start the engine and allow it to reach operating temperature. Check for leaks.
  46.  

Excel


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Fig. Fig. 3: Exploded view of the heater unit-Excel and Scoupe

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses and the evaporator drain hose.
  6.  
  7. Discharge and properly recycle the refrigerant from the air conditioning system.
  8.  
  9. Remove the suction and liquid tubes.
  10.  
  11. Remove the console.
  12.  
  13. Remove the glove box.
  14.  
  15. Remove the main lower crash pad and lower crash pad center facia panel.
  16.  
  17. Remove the heater control assembly.
  18.  
  19. Remove the lower crash pad center skin.
  20.  
  21. Remove the crash pad center support bracket.
  22.  
  23. Remove the evaporator unit.
  24.  
  25. Remove the rear heating joint duct.
  26.  
  27. Remove the heater unit.
  28.  
  29. Separate the case halves and remove the heater core.
  30.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the rear heating joint duct.
  6.  
  7. Install the evaporator unit.
  8.  
  9. Install the crash pad center support bracket.
  10.  
  11. Install the lower crash pad center skin.
  12.  
  13. Install the heater control assembly.
  14.  
  15. Install the main lower crash pad and lower crash pad center facia panel.
  16.  
  17. Install the glove box.
  18.  
  19. Install the console.
  20.  
  21. Install the suction and liquid tubes.
  22.  
  23. Properly evacuate, charge and leak test the air conditioning system.
  24.  
  25. Connect the heater hoses and the evaporator drain hose.
  26.  
  27. Fill the cooling system.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Start the engine and allow it to reach operating temperature. Check for leaks.
  32.  

Scoupe
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses and the evaporator drain hose.
  6.  
  7. Discharge and properly recycle the refrigerant from the air conditioning system.
  8.  
  9. Remove the suction and liquid tubes.
  10.  
  11. Disconnect the vacuum hose for the control panel.
  12.  
  13. Remove the console, cluster facia and left hand lower crash pad.
  14.  
  15. Remove the main lower crash pad and lower crash pad center facia panel.
  16.  
  17. Remove the center facia panel.
  18.  
  19. Remove the glove box.
  20.  
  21. Remove the heater control assembly.
  22.  
  23. Remove the center skin bracket.
  24.  
  25. Remove the rear heating joint duct.
  26.  
  27. Remove the evaporator.
  28.  
  29. Remove the heater unit.
  30.  
  31. Separate the case halves and remove the heater core.
  32.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the evaporator.
  6.  
  7. Install the rear heating joint duct.
  8.  
  9. Install the center skin bracket.
  10.  
  11. Install the heater control assembly.
  12.  
  13. Install the glove box.
  14.  
  15. Install the center facia panel.
  16.  
  17. Install the main lower crash pad and lower crash pad center facia panel.
  18.  
  19. Install the console, cluster facia and left hand lower crash pad.
  20.  
  21. Connect the vacuum hose for the control panel.
  22.  
  23. Install the suction and liquid tubes.
  24.  
  25. Connect the heater hoses and the evaporator drain hose.
  26.  
  27. Properly evacuate, charge and leak test the air conditioning system.
  28.  
  29. Fill the cooling system.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Start the engine and allow it to reach operating temperature. Check for leaks.
  34.  
  35. Check the air mix lever for ease of movement. Readjust air mix cable as necessary.
  36.  

1994-95 Elantra


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Fig. Fig. 4: Exploded view of the heater unit-1994-95 Elantra

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses and the evaporator drain hose.
  6.  
  7. Discharge and properly recycle the refrigerant from the air conditioning system.
  8.  
  9. Remove the suction and liquid tubes.
  10.  
  11. Remove the console.
  12.  
  13. Remove the glove box.
  14.  
  15. Remove the main lower crash pad and lower crash pad center facia panel.
  16.  
  17. Remove the heater control assembly.
  18.  
  19. Remove the lower crash pad center skin.
  20.  
  21. Remove the crash pad center support bracket.
  22.  
  23. Remove the rear heating joint duct.
  24.  
  25. Remove the heater unit.
  26.  
  27. Separate the case halves and remove the heater core.
  28.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the rear heating joint duct.
  6.  
  7. Install the crash pad center support bracket.
  8.  
  9. Install the lower crash pad center skin.
  10.  
  11. Install the heater control assembly.
  12.  
  13. Install the main lower crash pad and lower crash pad center facia panel.
  14.  
  15. Install the glove box.
  16.  
  17. Install the console.
  18.  
  19. Install the suction and liquid tubes.
  20.  
  21. Properly evacuate, charge and leak test the air conditioning system.
  22.  
  23. Connect the heater hoses and the evaporator drain hose.
  24.  
  25. Fill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and allow it to reach operating temperature. Check for leaks.
  30.  

1996-98 Elantra and Tiburon


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Fig. Fig. 5: Exploded view of the heater unit-1996-98 Elantra and Tiburon

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses.
  6.  
  7. Disconnect the vacuum hose from the nipple of the heater unit.
  8.  
  9. Remove the main crash pad assembly.
  10.  
  11. Remove the right front heating side duct and turn over the carpet.
  12.  
  13. Remove the right console mounting bracket.
  14.  
  15. Remove the left front heating side duct and turn over the carpet.
  16.  
  17. Remove the left console mounting bracket.
  18.  
  19. Remove the rear heating joint duct from the heater unit.
  20.  
  21. Disconnect the electrical harness from the control module mounted on the center facia panel support bracket.
  22.  
  23. Remove the center facia panel support bracket.
  24.  
  25. Remove the center support bars.
  26.  
  27. Remove the glove box support bracket.
  28.  
  29. Discharge and properly recycle the refrigerant from the air conditioning system.
  30.  
  31. Remove the evaporator unit.
  32.  
  33. Remove the heater unit.
  34.  
  35. Separate the case halves and remove the heater core.
  36.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the evaporator unit.
  6.  
  7. Properly evacuate, charge and leak test the air conditioning system.
  8.  
  9. Install the glove box support bracket.
  10.  
  11. Install the center support bars.
  12.  
  13. Install the center facia panel support bracket.
  14.  
  15. Connect the electrical harness to the control module mounted on the center facia panel support bracket.
  16.  
  17. Install the rear heating joint duct to the heater unit.
  18.  
  19. Install the left console mounting bracket.
  20.  
  21. Install the left front heating side duct and replace the carpet.
  22.  
  23. Install the right console mounting bracket.
  24.  
  25. Install the right front heating side duct and replace the carpet.
  26.  
  27. Install the main crash pad assembly.
  28.  
  29. Connect the vacuum hose from the nipple of the heater unit.
  30.  
  31. Connect the heater hoses.
  32.  
  33. Fill the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Start the engine and allow it to reach operating temperature. Check for leaks.
  38.  

Sonata


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Fig. Fig. 6: Heating, ventilation and air conditioning vacuum schematic-Excel and Sonata

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Disconnect the heater hoses and the evaporator drain hose.
  6.  
  7. Discharge and properly recycle the refrigerant from the air conditioning system.
  8.  
  9. Remove the suction and liquid tubes.
  10.  
  11. Remove the console and side covers.
  12.  
  13. Remove the glove box.
  14.  
  15. Remove the center crash pad cover, center crash pad and cassette assembly.
  16.  
  17. Remove the lower crash pad.
  18.  
  19. Remove the console mounting bracket and center support bracket.
  20.  
  21. Remove the rear heating duct assembly and rear heating joint duct.
  22.  
  23. Remove the heater control assembly.
  24.  
  25. Remove the heater assembly.
  26.  
  27. Separate the case halves and remove the heater core.
  28.  

To install:
  1. Join the case halves after installing the heater core.
  2.  
  3. Install the heater unit.
  4.  
  5. Install the heater control assembly.
  6.  
  7. Install the rear heating duct assembly and rear heating joint duct.
  8.  
  9. Install the console mounting bracket and center support bracket.
  10.  
  11. Install the lower crash pad.
  12.  
  13. Install the center crash pad cover, center crash pad and cassette assembly.
  14.  
  15. Install the glove box.
  16.  
  17. Install the side covers and console.
  18.  
  19. Install the suction and liquid tubes.
  20.  
  21. Properly evacuate, charge and leak test the air conditioning system.
  22.  
  23. Connect the heater hoses and the evaporator drain hose.
  24.  
  25. Fill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and allow it to reach operating temperature. Check for leaks.
  30.  

 
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