Kia_Sephia_Rio_Spectra_Optima_1998-2006

Heater Core

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Removal & Installation



Optima
  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 10 minutes for the SRS module to deplete its stored energy.

  4.  
  5. Recover the refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the expansion valve from the evaporator core and plug the lines.
  10.  
  11. Disconnect the heater hoses from the heater unit.
  12.  
  13. Remove the crash pad as follows:
    1. Remove the front seat.
    2.  
    3. Tilt the steering column down and remove the center facia panel.
    4.  
    5. Disconnect the trip sensor connector and remove the gauge cluster.
    6.  
    7. Remove the heater control unit.
    8.  
    9. Remove the radio unit.
    10.  
    11. Disconnect the damper from the glove box.
    12.  
    13. Remove the glove box from the lift, disconnect the pin and remove the glove box.
    14.  
    15. Remove the crash pad side cover.
    16.  
    17. Remove the center under cover.
    18.  
    19. Remove the console side cover.
    20.  
    21. Crash pad lower panel mounting.
    22.  
    23. Remove the A-pillar trim
    24.  
    25. Remove the photo sensor.
    26.  
    27. Disconnect the passenger air bag connector.
    28.  
    29. Remove the crash pad.
    30.  

  14.  
  15. Remove the cowl cross bar assembly.
  16.  
  17. Remove the heater unit.
  18.  
  19. Disconnect the heater from the blower unit.
  20.  
  21. Remove the heater core cover and remove the heater core.

    Click image to see an enlarged view

    Fig. Crash pad exploded view-Optima



    Click image to see an enlarged view

    Fig. Heater core from the heater unit-Optima

  22.  
  23. Installation is the reverse of removal.
  24.  
  25. Refill the cooling system to the correct level.
  26.  
  27. Start the engine and check for leaks.
  28.  

Rio
  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 10 minutes for the SRS module to deplete its stored energy.

  4.  
  5. Recover the refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the expansion valve from the evaporator core and plug the lines.
  10.  
  11. Disconnect the heater hoses from the heater unit.
  12.  
  13. Remove the crash pad as follows:
    1. Remove the front seat.
    2.  
    3. Tilt the steering column down and disconnect the trip sensor connector.
    4.  
    5. Remove the gauge cluster facia panel.
    6.  
    7. Disconnect the trim clips and remove the center facial panel.
    8.  
    9. Remove the fuse box cover.
    10.  
    11. Remove the lower crash pad panel mounting screws and remove the panel.
    12.  
    13. Remove the center lower tray.
    14.  
    15. Remove the lower center facia panel.
    16.  
    17. Disconnect the heater control cables and remove the heater control unit.
    18.  
    19. Disconnect the gauge cluster connector and remove the cluster.
    20.  
    21. Remove the radio assembly mounting screws and disconnect the audio connectors.
    22.  
    23. Remove the radio assembly.
    24.  
    25. Disconnect the damper from the glove box and remove the glove box.
    26.  
    27. Remove the left and right side crash pad side cover.
    28.  
    29. Remove air vents using a suitable pry tool.
    30.  
    31. Remove the A-pillar trim.
    32.  
    33. Remove the cowl side trim.
    34.  
    35. Remove the main crash pad assembly.
    36.  

  14.  
  15. Remove the cowl cross bar assembly.
  16.  
  17. Disconnect the heater unit electrical connectors.
  18.  
  19. Remove the heater unit.
  20.  
  21. Remove the heater core cover.
  22.  
  23. Remove the heater core.
    NOTE
    Take care not to bend the inlet and outlet pipes of the heater core during removal.



    Click image to see an enlarged view

    Fig. Crash pad exploded view-Rio

  24.  
  25. Installation is the reverse order of removal.
  26.  
  27. Fill the cooling system to the correct level.
  28.  
  29. Start the engine and check for leaks.
  30.  

Sephia
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 10 minutes for the SRS module to deplete its stored energy.

  4.  
  5. Position the front wheels in the straight-ahead position.
  6.  
  7. Remove the 4 steering wheel-to-air bag module bolts.
  8.  
  9. Remove the air bag module and disconnect the electrical connector.
  10.  
  11. Remove the steering wheel-to-steering column nut.
  12.  
  13. Remove the steering wheel from the steering column.
  14.  
  15. Remove the 2 screws and the glove box at the bottom of the glove box.
  16.  
  17. Remove the passenger side cover and pull the connector from the T bar side bracket.
  18.  
  19. Remove the 4 air bag module-to-instrument panel bolts.
  20.  
  21. Remove the air bag module, disconnect the electrical connector and remove the air bag module.
  22.  
  23. Drain the cooling system into a clean container for reuse.
  24.  
  25. Discharge and recover the air conditioning system refrigerant.
  26.  
  27. Remove the center panel trim.
  28.  
  29. Remove the console.
  30.  
  31. Remove the side cover.
  32.  
  33. Remove the lower left side cover.
  34.  
  35. Remove the steering column-to-instrument panel bolts and lower the steering column.
  36.  
  37. Remove the instrument cluster trim.
  38.  
  39. Remove the instrument cluster and disconnect the electrical connectors.
  40.  
  41. Remove the ventilation control panel and disconnect the electrical connectors.
  42.  
  43. Remove the radio and disconnect antenna and electrical connector.
  44.  
  45. Remove the center panel.
  46.  
  47. Disconnect the electrical harness connectors.
  48.  
  49. Remove the instrument panel-to-chassis bolts and remove the instrument panel.
  50.  
  51. Disconnect the control cable from the heater housing.
  52.  
  53. Disconnect the heater hoses from the heater core.
  54.  
  55. Remove the heater housing.
  56.  
  57. Remove the heater core from the heater housing.

    Click image to see an enlarged view

    Fig. Exploded view of the steering wheel and air bag module assembly-Sephia



    Click image to see an enlarged view

    Fig. Exploded view of the passenger-s side air bag module assembly-Sephia



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Sephia



    Click image to see an enlarged view

    Fig. View of the heater housing-Sephia

  58.  

To install:

  1. Install the heater core to the heater housing.
  2.  
  3. Install the heater housing.
  4.  
  5. Connect the heater hoses to the heater core.
  6.  
  7. Connect the control cable to the heater housing.
  8.  
  9. Install the instrument panel and the instrument panel-to-chassis bolts.
  10.  
  11. Connect the electrical harness connectors.
  12.  
  13. Install the center panel.
  14.  
  15. Connect the antenna and electrical connector and install the radio.
  16.  
  17. Connect the electrical connectors and install the ventilation control panel.
  18.  
  19. Connect the electrical connectors and install the instrument cluster.
  20.  
  21. Install the instrument cluster trim.
  22.  
  23. Install the steering column-to-instrument panel bolts.
  24.  
  25. Install the lower left side cover.
  26.  
  27. Install the side cover.
  28.  
  29. Install the console.
  30.  
  31. Install the center panel trim.
  32.  
  33. Install the passenger-s side air bag module and connect the electrical connector.
  34.  
  35. Install the 4 air bag module-to-instrument panel bolts and torque the bolts to 18-32 ft. lbs. (24-43 Nm)
  36.  
  37. Install the connector to the T bar side bracket and the side cover.
  38.  
  39. Install the glove box and the 2 screws at the bottom of the glove box.
  40.  
  41. Install the steering wheel to the steering column.
  42.  
  43. Install the steering wheel-to-steering column nut and torque the nut to 33 ft. lbs. (45 Nm)
  44.  
  45. Install the driver-s side air bag module and connect the electrical connector.
  46.  
  47. Install the 4 steering wheel-to-air bag module bolts and torque to 72-106 inch lbs. (8-12 Nm)
  48.  
  49. Refill the cooling system.
  50.  
  51. Connect the negative battery cable.
  52.  
  53. Evacuate, charge and leak test the air conditioning system.
  54.  
  55. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  56.  

Spectra
  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 10 minutes for the SRS module to deplete its stored energy.

  4.  
  5. Recover the refrigerant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect the heater hoses from the heater unit.
  10.  
  11. Remove the expansion valve from the evaporator core and plug the lines.
  12.  
  13. Remove the crash pad as follows:
    1. Remove the floor console assembly.
    2.  
    3. Remove the A-pillar trim.
    4.  
    5. Remove the cowl side trim.
    6.  
    7. Remove the left and right side crash pad side cover.
    8.  
    9. Remove the hood release handle.
    10.  
    11. Remove the left lower panel from the instrument panel.
    12.  
    13. Remove steering wheel and column cover.
    14.  
    15. Remove steering shaft from the cowl cross bar.
    16.  
    17. Remove the damper from the glove box.
    18.  
    19. Remove the hinge panels and remove the glove box.
    20.  
    21. Remove the instrument panel assembly main mounting bolts.
    22.  
    23. Disconnect the fuse box and radio antenna cable.
    24.  
    25. Remove the cluster facia panel.
    26.  
    27. Remove the instrument cluster.
    28.  
    29. Remove the center fascia panel.
    30.  
    31. Remove the heater control assembly.
    32.  
    33. Remove the radio assembly.
    34.  
    35. Remove the right lower panel from the instrument panel.
    36.  
    37. Remove the mounting bolts and remove the crash pad assembly.
    38.  

  14.  
  15. Disconnect the heater unit electrical connectors.
  16.  
  17. Remove the upper pipe bracket and side cover from the heater unit.
  18.  
  19. Pull the heater core from the heater unit.
    NOTE
    Take care not to bend the inlet and outlet pipes of the heater core during removal.



    Click image to see an enlarged view

    Fig. Crash pad exploded view - Spectra

  20.  
  21. Installation is the reverse order of removal.
  22.  
  23. Fill the cooling system to the correct level.
  24.  
  25. Start the engine and check for leaks.
  26.  

 
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