Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.

WARNING: Be sure to read and follow the "General Safety Information and Caution" before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries. Refer to GENERAL SAFETY INFORMATION AND CAUTION .

Shut off the High Voltage circuit (Refer to HIGH VOLTAGE SHUTOFF PROCEDURE .
Remove the air cleaner assembly and duct (Refer to Removal .
Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU (Refer to COOLANT .
Disconnect the coolant inlet hose (A) and outlet hose (B).
Remove the HPCU protector (C).

Fig 1: Coolant Inlet Hose, Outlet Hose & HPCU Protector
Courtesy of KIA MOTORS AMERICA, INC.
Measure the voltage between the inverter terminals to check that the capacitor in the inverter is discharged completely
1. Remove air cleaner assembly and air duct. (Refer to Removal )
2. Disconnect the inverter power cable (A).
  
  Fig 2: Inverter Power Cable
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Information
  
  Disconnect the inverter power cable as shown in the procedures below.
  
  Fig 3: Disconnecting Inverter Power Cable
  Courtesy of KIA MOTORS AMERICA, INC.
3. Measure the voltage between the inverter (+) terminal and the inverter (-) terminal.
  Less than 30V: High voltage circuit properly shut
  
  More than 30V: High voltage circuit faulty
  
  Fig 4: Measuring Voltage Between Inverter Terminals (1 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
  
  Fig 5: Measuring Voltage Between Inverter Terminals (2 Of 2)
  Courtesy of KIA MOTORS AMERICA, INC.
  
  WARNING:
  If measured more than 30V, check if the safety plug is removed completely. If measured more than 30V despite the safety plug is removed, it can be serious problems on the high voltage circuit. In this case, check DTC and never touch on the high voltage system.
Disconnect the motor power cable (A).

Fig 6: Motor Power Cable
Courtesy of KIA MOTORS AMERICA, INC.

Information

Disconnect the cable as the procedures below.

Fig 7: Disconnecting Motor Power Cable
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the HSG power cable (A).

Fig 8: HSG Power Cable
Courtesy of KIA MOTORS AMERICA, INC.

Fig 9: Disconnecting HSG Power Cable
Courtesy of KIA MOTORS AMERICA, INC.
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.
Disconnect the MCU connector (D).

Fig 10: Disconnecting MCU Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the HCU connector (A) and LDC connector (B).
Disconnect the LDC power outlet cable (C) and ground cable (D).

Fig 11: HCU & LDC Connector
Courtesy of KIA MOTORS AMERICA, INC.
Remove the installation bolts (A), and then remove the HPCU from the vehicle.

Fig 12: HPCU Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.