SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Heating, Ventilation & Air Conditioning Air Conditioning System
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REMOVAL AND INSTALLATION 
NOTE
Plug all of the open fittings immediately after removal in order to keep moisture out of the air conditioning system.
  1. Disconnect battery negative terminal.

  1. Discharge refrigerant from the air conditioning system.

  1. Disconnect fittings connected to the evaporator unit from the engine compartment.

  1. Remove the main crash pad assembly (Refer to the "BODY" section)

  1. Remove the glove box support bracket.

  1. Disconnect the thermostatic switch connector.

  1. Remove the evaporator upper and lower mounting bolts.

  1. Remove the evaporator unit.

  1. Installation is the reverse order of removal.

    NOTE
    1. While installing each of removed fitting, replace O-ring (if exists) and apply specified lubricant.
    2. Be careful not to bend or twist refrigerant lines in order to install them easily.
    3. After installation, evacuate, charge and test the air conditioning system.
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COMPONENTS 
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DISASSEMBLY 
  1. Remove clips (7EA) which is holding the upper case to the lower case.

  1. Remove the sponge pad which is wrapping around the evaporator inlet and the outlet fittings.

  1. Remove the evaporator upper case from the lower case.

  1. Remove the thermostatic switch (with thermistor) and thermistor mounting clip.

    CAUTION
    Be careful not to damage the fins of the evaporator core.
  1. Remove the evaporator core from the evaporator lower case.

INSPECTION
  1. Check for damaged fins of the evaporator core.

  1. Check for clogged fins of the evaporator core. If fins are clogged, clean them with compressed air.

    CAUTION
    Never use water to clean the evaporator core.
  1. Check fittings for cracks or scratches.

REASSEMBLY
  1. Reassembly is the reverse order of disassembly.

    CAUTION
    While reassembling the evaporator unit, be careful not to damage the fins of the evaporator core and the thermostatic switch wiring.
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COMPONENTS 
ON-VEHICLE INSPECTION
  1. Check quantity of refrigerant gas during refrigeration cycle.

  1. Install manifold gauge set.

  1. Run the engine at 2,000 rpm at least 5 minutes.

  1. Read the manifold gauge and check the gas leakage from the evaporator by using gas leak detector.

    • If the expansion valve is clogged, low pressure reading will drop to 0 kg/cm2, otherwise it is ok.
    • If the expansion valve is clogged or gas leak from the evaporator, then repair or replace as necessary.