Tucson 2006-2008

Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions Section.
  3. Recover the refrigerant with a recovery/recycling/charging station.
  5. When the engine is cool, drain the engine coolant from the radiator.
  7. Disconnect the negative cable from the battery.
  9. Remove the bolts (A) and the expansion valve (B) from the evaporator core. Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

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    Fig. Removing the evaporator core

  11. 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.

  13. Remove the crash pad.
  15. Remove the cross member.
  17. Remove the mounting nut (A), the mounting bolts (B), and heater and evaporator unit (C).

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    Fig. Heater and evaporator unit illustrated

  19. Remove the side bracket (C).
  21. Remove the clip and lower cover. Be careful not to bend the inlet and outlet pipes during heater core and evaporator core removal.

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    Fig. Side bracket removal

  23. Disconnect the 7P connector (A) from the temperature actuator (C). Remove the self-tapping screws (B) and the temperature actuator (C) from the heater unit.

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    Fig. Removing temperature actuator

  25. Installation is the reverse order of removal, and note these items:

    Make sure temperature actuator runs smoothly
    If you're installing a new evaporator, add refrigerant 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 and check for leaks