"NOTE: THIS WILL WORK ON 95 UP TO SOME 2000'S IT APPEARS TO HAVE CHANGED IN 2000 (USA MODELS AT LEAST) SO LOOK FIRST BEFORE TEARING APART EVERYTHING. SEE PICTURES ON SECOND PAGE OF THIS THREAD FOR OTHER TYPE " EDITED 10/29/2011
I have performed this procedure 2 times and have heard from 10 others that it has worked for them. It was not my idea but a guy on 4x4wire.com Kia forum whose handle is Dorkpunch.
Anyway, here it is:
Take out the battery and the plastic tank on the back side of the crossover tube to gain easier access to the clamps on the hoses. I found it easier to replace the clamps with standard hose clamps. You might also want to replace the hoses if they are old. I used standard heater hose or you can buy factory hoses. Remove the glove box and steel bar. You will also need to loosen up some of the screws for the center console and dash. Look at the pictures and you will see what you have to get to.
The hump is at an angle, you cut the hump off carefully (using a carpet knife or similar) and then push/pull the heater core out, while you have the heater core out, clean as much coolant as possible out of the hvac box as you can. I used SimpleGreen. Then slide the new heater core in and attach the hoses. Use RTV silicone sealer to attach and reseal hump back onto hvac box.. Use tape to hold in place while silicone is setting up, then reassemble dash.. Remove tape after a couple of hours.
You will smell the RTV for about 2 days.
If you haven't purchased a heater core yet, some of the best prices I've found for heater cores is from: RockAuto Auto Parts
I have used the one they sell for a 1996, they show one PROLIANCE Part # 394185. This is the one I bought for my 2000 and it fit. [B]UPDATE: Now this heater core is leaking...So I bought another one from ROCKAUTO and the new one is ALL METAL...it looks as if it should last. The Proliance brand is no longer sold by them... wonder why????
DISCLAIMER: IF YOU STILL USE ROUNDED END SAFETY SCISSORS, DON'T ATTEMPT THIS. I AM NOT RESPONSIBLE FOR ANY INJURY TO YOU OR OTHERS OR DAMAGE DONE TO YOUR VEHICLE BECAUSE OF MY OR YOUR INCOMPETENCE.
This is not a difficult job and should take about 2 cocktails and use standard tools.
Several people have done this and are very happy with the outcome, and if you are one of them, please post your experience.
This procedure will save you several hundred dollars or several hours.
If you use this and find any other helps, post them.
AND, if you need a LIFTKIT for your Sportage, check out got lift?