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Home >> Hyundai >> 2012 >> Sonata GLS, Automatic Trans >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (Hybrid Control System (HEV)) >> HPCU (Hybrid Power Control Unit) >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.
WARNING: This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution (Refer to "SAFETY PRECAUTION ").
  1. Shut off the High Voltage circuit (Refer to "HIGH VOLTAGE SHUTOFF PROCEDURE " ).
  2. Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU (Refer to "HYBRID MOTOR COOLING SYSTEM " ).
  3. Remove the air cleaner assembly and duct (Refer to "INTAKE AND EXHAUST SYSTEM " ).
  4. Disconnect the coolant inlet hose (A) and outlet hose (B).
  5. Remove the HPCU protector (C).
    Fig 1: Locating Coolant Inlet Hose, Outlet Hose And HPCU Protector
    G07319589Courtesy of HYUNDAI MOTOR CO.
  6. Disconnect the power cable (A) from the HPCU.
    1. Pull the lever (B) in the direction of the arrow with the hook (C) pressed.
    2. Press the lever (D), and then pull the power cable connector.
      Fig 2: Locating Power Cable Of HPCU
      G07319590Courtesy of HYUNDAI MOTOR CO.
      Fig 3: Locating Hook And Lever
      G07319591Courtesy of HYUNDAI MOTOR CO.
  7. Disconnect the motor power cable (A).
    1. Pull the lever (B), and then pull the connector by rotating the lever (C).
  8. Disconnect the HSG power cable (D).
    1. Pull the lever (E) in the direction of the arrow.
    2. Press the hook (F), and then pull the motor power cable connector.
      Fig 4: Locating Lever And Hook
      G07319592Courtesy of HYUNDAI MOTOR CO.
  9. Disconnect the electric A/C compressor power cable (A).
    1. Pull the lever (B) in the direction of the arrow.
    2. Press the hook (C), and then pull the motor power cable connector.
  10. Disconnect the MCU connector (D).
    Fig 5: Locating Lever And Hook
    G07319593Courtesy of HYUNDAI MOTOR CO.
  11. Disconnect the HCU connector (A) and LDC connector (B).
  12. Disconnect the LDC power outlet cable (C) and ground cable (D).
    Fig 6: Locating HCU Connector, LDC Connector, LDC Power Outlet Cable And Ground Cable
    G07319594Courtesy of HYUNDAI MOTOR CO.
  13. Remove the installation bolts (A), and then remove the HPCU from the vehicle.
    Fig 7: Locating HPCU Installation Bolts
    G07319595Courtesy of HYUNDAI MOTOR CO.
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