[constantinos]

Hi guys and congrats to this amazing forum for hepling each other!
Im glad to be in this i30 family for 10 years:)

i have an i30 2008 1.6 Crdi and my one of the less issue i have is that i want to change the HEAT EXCHANGER of my car.
Does anyone has any idea if i ahave to remove the hole dashboard or is any easiest way..

thanks

[tw2005]

Wow, let me say a little prayer for you. You're definitely going to need to remove the entire HVAC system I suspect as it'll be housed within that. Will the crashpad have to come out? Good question, I wish I could remember now but quite likely.

I'll dive into the manual and see what it reveals. has the coolant been kept in good condition in this vehicle?

[tw2005]

wWIthgout going into great detail, you're Not going to like this but manual states entire HVAC unit needs to come out and for that the aircon system needs to be disconnected too, so that'a an evac + regas and also states crash pad to be removed too.

Whether someone has found another way I can't say.

"The Great Detail"

. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/ recycling/ charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
4. Remove the expansion valve cover(A).

 
5. 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.
 
6. 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.
 
7. Remove the crash pad (Refer to BD group-cresh pad).
8. Remove the cowl cross bar assembly. (Refer to BD group-cresh pad)
9. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator temperature sensor.
10. Remove the heater ＆ blower unit after loosening 3 mounting nuts.

 
11. Remove the blower unit (B) from heater unit after loosening 3 screws.

 
12. Remove the heater core (B) after remove the cover (A).

 
13. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.

 
14. Remove the heater unit lower case(A).

 
15. Remove the evaporator core(A).

 
16. Install the heater core in the reverse order of removal.
17. Installation is the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
B. 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.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. 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.
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolant.
 

[tw2005]

[constantinos]

THANK YOU ALL GUYS,...even if i put the problem in a wrong "partition" of the forum   your fast answers are relly helpfull!!!
i already disassemply the hole dashboard and im waiting a friend  help me to  remove it.
I will also read again the manual that you sent me..

thanks a lot and happy easter to all of you!!!

Constantinos

[tw2005]

THANK YOU ALL GUYS,...even if i put the problem in a wrong "partition" of the forum   your fast answers are relly helpfull!!!
i already disassemply the hole dashboard and im waiting a friend  help me to  remove it.
I will also read again the manual that you sent me..

thanks a lot and happy easter to all of you!!!

Constantinos

Take care, there's a lot of wiring and could be a sensor or two tucked into that crash pad where that dome is. I think I broke that when I pulled the guts out but it was a wreck I was stripping out. Take heaps of photos too I reckon as you dismantle. The way I read it, that entire cross bar also comes out, and there'll be harnesses clipped in everywhere. 

[constantinos]

yes i relize that it would be a long day for me;( should i remove the evaporator also to install the new heat exchanger???
i already unistall and bypass the heater so no coolant inside...

thans for the warnings btw!

[tw2005]

yes i relize that it would be a long day for me;( should i remove the evaporator also to install the new heat exchanger???
i already unistall and bypass the heater so no coolant inside...

thans for the warnings btw!

Does it say so in that list I put up? The whole HVAC unit is coming out in one piece, that contains the Evap and heater core/s. There's also an electric heter in there as well I believe.

That's why the A/C will be discharged or evacuated so you can disconnect the piping and withdraw the whole unit. Then you'll find the heater core will be in compartemnet of the HVAC casing, check the drawings out.

EDIT: It does mention removing the EVAP, I can't answer this further as I have not disassembled the HVAC. I've totally stripped out the cabin and that's about it. You'll work it out when you get there.

[constantinos]

yes i already remove the electric heater...
do you have any fotos or remember how many screws are im cowl cross bar? i already remove the 4 each side one behind the radio and 2 on the engine compartment...
im a good helicopter engineer but as it seems  not good enough in cars 

[tw2005]

yes i already remove the electric heater...
do you have any fotos or remember how many screws are im cowl cross bar? i already remove the 4 each side one behind the radio and 2 on the engine compartment...
im a good helicopter engineer but as it seems  not good enough in cars 

No  I don't. looks like it'll have bolts left and right sides, centre at floor and firwewall and around glovebox could be some extras. RHD model , not going to see much maybe you can zoom in but the bar is removed in this

[constantinos]

Hi again mate
I finally did it....
And yes defenitly you have to remove the expansion valve of A/C and u need new o rings etc!!i can say that it was one of the hardest hob ive done!
But again thanks all for your help.
Hope to coorperate again!:)

P.S tip for that job...remove the steering wheel (all of it) it helps a lot to remove and install the new heater!

[tw2005]

Hi again mate
I finally did it....
And yes defenitly you have to remove the expansion valve of A/C and u need new o rings etc!!i can say that it was one of the hardest hob ive done!
But again thanks all for your help.
Hope to coorperate again!:)

P.S tip for that job...remove the steering wheel (all of it) it helps a lot to remove and install the new heater!

Cheers. love the pics, really love it when people give us real data to learn from

[tw2005]

Oh yeah, RHD. Where are you ? I thought you were in Europe.

[constantinos]

HAHA yes im in Europe!!:) Cyprus exactly!!!
I didnt take more photos cause i couldnt! I was busy holding the cross bar!! 

[tw2005]

HAHA yes im in Europe!!:) Cyprus exactly!!!
I didnt take more photos cause i couldnt! I was busy holding the cross bar!! 

Typical, I thought Greece and then saw RHD and wondered I bet it's Cyprus but then was wondering if I missed something and you were on this side of the world

[marti30]

I hope it's not too late to add my words of dubious wisdom. A tried and trusted independent garage replaced the heater matrix on my 2009.5 model year UK spec rhd 1.6 u2 crdi without removing the dashboard. Their 'alternative' method involved cutting off most of the rigid pipes and replacing them with flexible hose. As well as greatly reducing the labour time they saved me more money by using a pattern part.