5NP-D4B5F-04

GROUP
NUMBER
HVAC
Technical Service Bulletin
DATE
17-HA-001
MODEL(S)
MARCH 2017
SUBJECT:
SONATA (YF)
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
This TSB supersedes TSB 16-HA-001 to clarify how to determine the applicable part number.
Description: Some Sonata (YF) vehicles may develop a condition with the separator plate in the
middle of the heater box (Heater & Evaporator Assembly) becoming warped and may cause
interference against one or more of the internal flaps that control air flow to the vents.
This condition may result in HVAC system exhibiting abnormal noise from the heater box, difficulty to
control the vented temperature, blocked airflow due to improper mode control, and/or airflow stuck in
defrost mode.
Follow the procedure outlined in this bulletin to replace the heater box separator to repair this condition.
Applicable Vehicles: 2011-2014MY Sonata (YF) 2.0T and 2.4L vehicles
Parts Information:
Part Name
Heater Box
Separator
Foam Seals
Part Number
Note
97203-3S000
97206-3S000
Use Full VIN to determine
correct replacement part
number from the catalog.

Foam seal parts
applicable to all model
years and HVAC types.

Not required to perform
this repair.
(Only replace if damaged.)
Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair
SUBJECT:
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
Warranty Information:
Model
Op Code
Operation
Sonata
97206R00
(YF)
HEATER BOX
SEPARATOR
Op Time
Causal Part
Nature
Cause
Refer to
Web LTS
for current
LTS time
97203-3S000 or 97206-3S000
(Use applicable Part Number)
I52
ZZ3
NOTE: Use appropriate Causal Part according to the Full VIN find from EPC. Normal warranty applies.
Service Procedure:
1.
Refer to the service procedure published in
the Shop Manual to properly remove the
Heater & Evaporator Assembly.

2.
Shop Manual Section:
Heating, Ventilation, Air Conditioning 
Heater Unit  Repair Procedures
Remove the (2) screws from the heater core
cover over the heater core tubes using a
Philips screwdriver, and then remove the
heater core from the assembly.
TSB #: 17-HA-001
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SUBJECT:
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
3.
Remove the (8) screws from the plastic
cover over the A/C evaporator using a
Philips screwdriver, and then remove the
plastic cover and the A/C evaporator.
4.
Carefully remove and save the short middle
foam seal which covers the joint between
the two case halves to be reinstalled later.

5.
Replace the seal (refer to Parts
Information) if it is damaged or does not
reattach securely during reassembly.
Using a sharp cutting blade, cleanly cut both
of the large rectangular seals immediately
over the joint between the two case halves.

Replace the seals (refer to Parts
Information) if it does not reattach
securely during reassembly.
TSB #: 17-HA-001
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SUBJECT:
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
6.
Using a putty knife or a gasket scraper,
carefully loosen the white insulation pad
from one side of the Heater & Evaporator
Assembly to expose the joint between the 2
case halves.
7.
Remove the (4) screws holding the two case
halves together.


8.
Several screws are deep in recesses, so
a long magnetic screwdriver is helpful.
It may be necessary to remove one or
more of the actuators to access the
screws.
Use a flat blade screwdriver or a suitable
prying tool to remove the (9 total) Case to
Case Clips holding the two case halves
together.

Keep all (9 total) Case to Case Clips for
later reinstallation.
TSB #: 17-HA-001
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9.
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
Separate the two case halves.

It may be necessary to move the internal
flaps to align them with the access slots.
10. Remove the Heater Box Separator and
replace it with a new part.
REPLACE
11. Slide the two case halves back together.
NOTICE
Ensure that the pivots for the
internal flaps are positioned
correctly together and the case
halves are not misaligned.
TSB #: 17-HA-001
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SUBJECT:
HVAC HEATER BOX SEPARATOR REPLACEMENT PROCEDURE
12. Reinstall the (9) Case to Case Clips and all
the screws that secure the case halves
together.

Reinstall any actuators that were
removed during the diassembly.

Reinstall the short middle foam seal that
was previously removed during Step 4.
13. Use a suitable adhesive (such as a spray
type) to reattach the white insulation pad to
the original position on the Heater &
Evaporator Assembly.
14. Refer to the service procedure published in the Shop Manual to properly reinstall the Heater &
Evaporator Assembly.

Shop Manual Section:
Heating, Ventilation, Air Conditioning  Heater Unit  Repair Procedures
15. Verify correct operation of the Heater & Evaporator Assembly before completing this repair.
 Check for abnormal noise and confirm airflow while changing between vent direction modes.
 Check for normal airflow changes while adjusting set temperature from full cold to full hot.
o Independently check driver and passenger sides if equipped with dual zone FATC.
 Check for abnormal noise and confirm airflow while changing between FRESH/RECIRC intake.
 Check the proper connection and routing of the A/C evaporator drain hose.
TSB #: 17-HA-001
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