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 .
Be sure to shut off the high voltage circuit according to the "High Voltage Shut-off Procedures" before doing any work related with the high voltage system to avoid serious electrical injuries. Refer to HIGH VOLTAGE SHUT-OFF PROCEDURE .

NOTE:

The MCU is integrated into the HPCU that can't be disassembled. So refer to "HPCU (HYBRID POWER CONTROL UNIT) " for the removal or installation procedure of the MCU.

Shut off the High Voltage circuit (Refer to HIGH VOLTAGE SHUTOFF PROCEDURE .
Remove the under cover (A).
Tightening torque:

7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

Fig 1: Under Cover
Courtesy of KIA MOTORS AMERICA, INC.
Drain the coolant of hybrid motor cooling system. (Refer to COOLANT ) .
Remove the air duct (A).
Tightening torque :

7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

Fig 2: Air Duct
Courtesy of KIA MOTORS AMERICA, INC.
Remove the air cleaner assembly.
1. Disconnect the breather hose (A).
2. Disconnect the air intake hose (B) and then remove the air cleaner assembly (C).
  Tightening torque:
  
  Hose clamp bolt:
  
  2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~ 3.6 lb-ft)
  
  Air cleaner assembly bolts:
  
  7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
  
  Fig 3: Breather Hose, Air Intake Hose & Air Cleaner Assembly
  Courtesy of KIA MOTORS AMERICA, INC.
  NOTE:
  - When installing the air intake hose, the plate of the hose clamp must be in line with the stopper of the hose.
  - When installing the air intake hose, the center of the mark of hose must be in line with the throttle body rib.
    
    Fig 4: Air Intake Hose Installation Position
    Courtesy of KIA MOTORS AMERICA, INC.
Remove the reservoir. (Refer to "RESERVOIR ")
Remove the coolant inlet hose (A) and outlet hose (B).
Remove the HPCU protector (C).

Fig 5: HPCU Protector, Coolant Inlet And Outlet Hose
Courtesy of KIA MOTORS AMERICA, INC.
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 6: Power Cable Of HPCU
  Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the motor power cable (A).
1. Pull the lever (B), and then pull the connector by rotating the lever (C).
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 7: Pulling Lever
  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 8: Disconnecting Electric A/C Compressor Power Cable
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).
Tightening torque:

(C, D) 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

Fig 9: HCU Connector, LDC Connector, LDC Power Outlet Cable And Ground Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the installation bolts (A), and then remove the HPCU from the vehicle.
Tightening torque:

19.6 ~ 29.4 N.m (2.0 ~ 3.0 kgf.m, 14.5 ~ 21.7 lb-ft)

Fig 10: Installation Bolts Of HPCU
Courtesy of KIA MOTORS AMERICA, INC.