Repair Procedures: Removal

WARNING:

Be sure to read and follow the "GENERAL SAFETY INFORMATION & CAUTION " before doing any work related with the high voltage system. Failure to follow the safety instructions may result in serious electrical injuries.
Be sure to shut off the high voltage before doing any work related with the high voltage system (Refer to "HIGH VOLTAGE SHUT-OFF PROCEDURE "). Failure to follow the safety instructions may result in serious electrical injuries.

Information

When replacing the high voltage junction block, normal charger (On-Board Charger) and Electric Power Control Unit (EPCU), replace with a new part if there is any damage, deformation or serious contamination on the following parts.
(Motor↔EPCU sealing gasket, EPCU↔3-phase sealing cover gasket, EPCU↔side sealing cover gasket, EPCU↔OBC Water way sealing gasket and High voltage junction box gasket)

Shut off the high voltage.
(Refer to Vehicle Control System - "HIGH VOLTAGE SHUT-OFF PROCEDURES ")
Remove the drain plug and discharge the coolant.
(Refer to Electric & High Voltage Battery Cooling System - " COOLANT ")
Disconnect the PTC heater pump connector (A).
Disconnect the high voltage junction box connector (B).
Disconnect the on-board charger input connector (C).
Disconnect the quick charge cable connector (D).

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Disconnect the high voltage junction box connector (A).

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Disconnect the A/C compressor high voltage cable (A).

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Remove the on-board charger side cover (A) and electric power control unit side cover (B).
Tightening Torque : 3.9 - 5.9N.m(0.4 - 0.6 kgf.m, 2.9 - 4.3lb.ft)

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Remove the on-board charger mounting bolt (A) and electric power control unit mounting bolt (B).
Tightening Torque:
1. 3.9 - 5.9N.m(0.4 - 0.6 kgf.m, 4.3 - 6.8lb.ft)
2. 8.8 - 9.8N.m(0.9 - 1.0 kgf.m, 6.5 - 7.2lb.ft)
CAUTION:
- Make sure not to let the bolts fall inside.
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Remove the high voltage joint box after removing the bolt (A).
Tightening Torque : 15.7 - 23.5N.m(1.6 - 2.4 kgf.m, 11.6 - 17.4lb.ft)

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Disconnect the on-board charger cooling hose (A).

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Disconnect the electric power control unit signal connector (A).

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Loosen the mounting bolt (A) and then remove the cooling pipe mounting bracket from the on-board charger.
Tightening Torque : 8.8 - 10.7N.m(0.9 - 1.1 kgf.m, 6.5 - 7.9lb.ft)

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Remove the on-board charger after loosening the mounting bolt (A)
Tightening Torque : 19.6 - 23.5N.m(2.0 - 2.4 kgf.m, 14.4 - 17.3lb.ft)

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Disconnect the electric power control unit cooling hose (A).
Remove the electric power control unit "+" cable (B) after loosening the mounting bolt (D).
Tightening Torque : 8.8 - 10.7N.m(0.7 - 1.0 kgf.m, 6.5 - 7.9lb.ft)
Disconnect the Low Voltage DC/DC Converter "-" cable (C).

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Disconnect the electric power control unit connector (A).
Remove the electric water pump after loosening the mounting bolt (B).
Tightening Torque : 19.6 - 23.5N.m(2.0 - 2.4 kgf.m, 14.4 - 17.3lb.ft)

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Remove the three phase cover assembly (A) after loosening the mounting bolts (4EA).
Tightening Torque : 3.9 - 5.8N.m(0.4 - 0.6 kgf.m, 2.8 - 4.3lb.ft)

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Remove the electric power control unit (C) after loosening the mounting bolt (A, B).
Tightening Torque:
1. 8.8 - 10.7N.m(0.9 - 1.1 kgf.m, 6.5 - 7.9lb.ft)
2. 49.0 - 63.7N.m(5.0 - 6.5 kgf.m, 36.1 - 47.0lb.ft)
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