Finding myself with the problem of a very leaky heater core on my 1996 Sportage I decided I should investigate just exactly what would be involved with replacing it. There were quite a few good tips on the Sportage Forum, notably from Nukeiridium, and they were very informative.

What it all boiled down to it seems was the difficulty lay in removing the heater/cooling box. This involved the breaking of the A/C seal by removing the compressor hoses. It seems like a lot and it is. I was resigned to the inevitable. It had to be done.

I went over to the Kia Motors site and mucked about finding out how to remove the dash. Removing turned out easier than I expected. Once the dash was out I figured out where the heater core was located. It was behind a rectangle shaped protrusion, bent slightly to the left, on the heater control box. I noticed it was plastic, and very flexable plastic at that. It gave me an idea.

Rummaging around in my toolbox I found my carpenter's knife. I inserted a brand new blade and went to work.

The part of the heater box that holds the heater core sticks out about an inch or so. I cut into the plastic very easily halfway between the box and the end of the heater core protrusion. I wasn't worried about hurting anything underneath the cut since the only thing underneath it was the old heater core I was replacing. Trying my best to make as even cut all around I pulled the "cover" off. There was the old heater core staring at me.

The next thing was to remove the the heater hoses from the old heater core. I found that following the instructions on this forum for removing the spark plugs and for cleaning the throttle body to be helpful here. Once these items were removed I had a pretty clear shot of the hose clamps to the heater core.

Once the hoses were removed I went back and pulled out the old heater core. I then inserted the new heater core. This took about 10 seconds or less.

With the new heater core in I had my brother Al hold the heater core in while I went and put the heater hoses back on the new heater core. If someone isn't holding it in the core will tend to move away from you while you're trying to push the hoses on the new core. That done it was onto the next step.

Lightly sanding any rough stuff off the heater box and the heater "cover" I just created, I gobbed it with glue. I used some stuff I had around. You can use whatever floats your boat -- gorilla glue, etc.

Then I grabbed the old handyman's friend, duct tape, to tape and hold the cover in place while it dried. That done I finished it all up with a big bead of RTV on top on the glue. Not really much needs to be done here since there is no pressure to speak of on the back of the heater core, nor does the end of it support anything. You're just trying to make and keep an airtight seal, that's all.

After that it was put the dash back in, clean the throttle body (since it was already out) and change the spark plugs because -- why not?

I hope this helps someone someday.


Stanley

Some Pics:


Here is the heater core hiding place.


"Cover" is cut and removed.


The old heater core out. The new one goes in the same way.


Out and on the way to the trash.


Special heater core removal tool.


Some glue I used. Use whatever you think best.


Handyman's Friend.


Brother Al helps Out. A lot!

AWESOME WRITEUP!!! Good idea with the carpet knife <img src="/forums/images/graemlins/kewl.gif" alt="" /> I am going to check out what type of plastic the box is so I can offer advice on what the best type of glue to use would be. It looks like you used a 2 part epoxy. That should do the trick for the most part.
How many hours did it take you? You might include url's to the site that told you how to remove the dash.
And I take it that your way doesn't require removing the AC hoses!! That will be great.
What brand core did you end up using? Were the ends crimped or glued on?

Again, THANKS for the detailed writeup.

Everet <img src="/forums/images/graemlins/patriot.gif" alt="" />

LOL! I love the Canadian content!

Was going to do my heater core on mine in a week or two, will try your idea!

do you think it would be posible to cut firewall and pull core into engine compartment? i really dont want to remove my dash.i dont need one yet ,but i will someday im sure.

Clever, good work and excellent information. <img src="/forums/images/graemlins/kewl.gif" alt="" />

OutStanding! <img src="/forums/images/graemlins/patriot.gif" alt="" />

Thanks for your reply.

We started after breakfast and were finished by lunch. Maybe 5 hours. But beer was involved near the end.

I can't link to the exact page because of the way Kia set up the site. Go to Kia Tech Info

No, you don't have to deal with the AC system at all. It doesn't enter into the job one bit.

I don't remember what brand but it was but I know it wasn't the cheap brand. I used a good automotive parts supplier for this job since I had no desire to go back in and do it over. Regular stuff I can go to Auto Zone for.

The ends were crimped.

Stanley

You don't have follow all of the instructions from Kia on pulling the dash to get to the heater core, stuff like pulling the steering wheel, steering column and front seats and such. Just get the dash out and you're on your way.

Also, disconnect the battery and then turn on your headlight switch to drain any remaining power in the computer. You have to disconnect the air bags and you might set a fault only the dealer can clear.

If possible, let me know how it works out for you. I probably left something out of my explanation somewhere.


Stanley

No.

i was afraid of that. very good write up and pics. will come in handy for many,thanks!