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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2017 Kia Soul EV. However, it is still accessible from the selected car via links, so may be relevant.
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.
  • 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.

CAUTION:
  • Put on gloves to protect your hands.
NOTE:
  • When prying with a flat-tip screwdriver, wrap it with protective tape, and apply protective tape around the related parts, to prevent damage.
  • Use a plastic panel removal tool to remove interior trim pieces to protect from marring the surface.
  • Take care not to bend or scratch the trim and panels.
  1. Recover the refrigerant with a recovery/recycling/charging station.
    CAUTION:
    • Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
    • Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
    • If PAG oil mixes into the POE oil of the system, dielectric breakdown may occur due to decreased volumetric resistivity and the A/C compressor may not work.
  2. Disconnect the negative (-) battery terminal.
  3. Shut off the high voltage circuit. (Refer to EV Battery System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
  4. Remove the cowl top cover.

    (Refer to "COWL TOP COVER ""Cowl Top Cover")

  5. Remove the pipe (A) after loosening the mounting bolts.
    Fig 1: Locating Pipe With Mounting Bolts
    G11938406Courtesy of KIA MOTORS AMERICA, INC.
  6. Remove the expansion valve (A) after loosening the mounting bolts from the evaporator core.

    Tightening Torque: 

    7.8 ~ 11.7 N.m (0.8 ~ 1.2 kgf.m, 5.7 ~ 8.6 lb-ft)

    Fig 2: Locating Expansion Valve With Mounting Bolts
    G11938407Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION:
    • Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
    • Replace the O-rings with new ones.
  7. Loosen the cowl cross member mounting bolts (A).
    Fig 3: Locate Locating Cowl Cross Member Mounting Bolts
    G11938408Courtesy of KIA MOTORS AMERICA, INC.
  8. Remove both sides of front seat assembly.

    (Refer to Body - "FRONT SEAT ASSEMBLY ")

  9. Remove the floor console assembly.

    (Refer to Body - "FLOOR CONSOLE ASSEMBLY ")

  10. Remove the crash pad lower panel.

    (Refer to Body - "CRASH PAD LOWER PANEL ")

  11. Remove the glove box housing.

    (Refer to Body - "GLOVE BOX HOUSING ")

  12. Remove the crash pad center panel.

    (Refer to Body - "CRASH PAD CENTER PANEL ")

  13. Remove both sides of the front pillar trim.

    (Refer to Body - "FRONT PILLAR TRIM ")

  14. Remove both sides of the cowl side trim.

    (Refer to Body - "COWL SIDE TRIM ")

  15. Remove the steering column shroud lower panel.

    (Refer to Body - "STEERING COLUMN SHROUD PANEL ")

  16. Remove the steering wheel.

    (Refer to the appropriate service information.STEERING COLUMN SHROUD PANEL , STEERING GEAR RACK, LINKAGE AND BOOTS - "Steering Wheel")

  17. Remove the multifunction switch.

    (Refer to MULTIFUNCTION SWITCH REMOVAL "Multifunction Switch")

  18. Lower the steering column after loosening the mounting bolts.

    (Refer to the appropriate service information. STEERING COLUMN SHROUD PANEL , STEERING GEAR RACK, LINKAGE AND BOOTS "Steering Column and Shaft")

  19. Remove the rear air-duct assembly (A).

    [LH] 

    1. Remove the accelerator pedal fixing cap (A).
      Fig 4: Locating Accelerator Pedal Fixing Cap
      G11938409Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      Fig 5: Locating Accelerator Pedal With Mounting Bolt
      G11938410Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 6: Locating Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G11938411Courtesy of KIA MOTORS AMERICA, INC.
    4. Bend the front floor carpet backwards.
    5. Remove the rear air duct assembly (A) after loosening the mounting nut.
    Fig 7: Locating Rear Air Duct Assembly With Mounting Nut
    G11938412Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 8: Locating Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G11938413Courtesy of KIA MOTORS AMERICA, INC.
    2. Bend the front floor carpet (A) backwards.
      Fig 9: Locating Front Floor Carpet
      G11938414Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the rear air duct assembly (A) after loosening the mounting nut.
    Fig 10: Locating Rear Air Duct Assembly With Mounting Nut
    G11938415Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the shift lever assembly.

    (Refer to Automatic Transaxle System - "SHIFT LEVER ")

  21. Disconnect the airbag control module (SRSCM) connector (A).
    Fig 11: Locating Airbag Control Module Connector
    G11938416Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    Fig 12: Locating Cowl Cross Bar Center Bracket With Mounting Bolts And Nuts
    G11938417Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    Fig 13: Locating Passenger Compartment Junction Box Connectors
    G11938418Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    Fig 14: Locating Passenger Compartment Junction Box Mounting Clips
    G11938419Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's] 

    Fig 15: Locating Multi Box Connectors - Driver'S
    G11938420Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 16: Locating Multi Box Connectors - Passenger'S
    G11938421Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    Fig 17: Locating Front Pillar Connector And Mounting Clips - Driver'S
    G11938422Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 18: Locating Front Pillar Connector And Mounting Clips - Passenger'S
    G11938423Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    Fig 19: Removing Drain Hose
    G11938424Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    Fig 20: Locating High Voltage PTC Heater Cable
    G11938425Courtesy of KIA MOTORS AMERICA, INC.

    Information 

    • How to press the high voltage PTC heater cable locker pin
    1. Pull the lock pin (A) in the direction of the arrow.
      Fig 21: Pulling Lock Pin
      G11938426Courtesy of KIA MOTORS AMERICA, INC.
    2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
    Fig 22: Pressing Locker Pin Using Flat Driver On Hole
    G11938427Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    Fig 23: Locating Main Crash Pad And Cowl Cross Bar Assembly With Bolts
    G11938428Courtesy of KIA MOTORS AMERICA, INC.
  30. Disconnect the heater and blower unit connectors.
    1. Remove the high voltage heater ground (A) after loosening the mounting bolt (B) and fixing clip (c).
      Fig 24: Locating High Voltage Heater Ground, Mounting Bolt And Fixing Clip
      G11938429Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
      Fig 25: Locating Intake Actuator Connector And Fixing Clip
      G11938430Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the fixing clip (B) after disconnecting the blower unit connector (A).
      Fig 26: Locating Blower Unit Connector And Fixing Clip
      G11938431Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
      Fig 27: Locating PWM Unit Connector And Fixing Clip
      G11938432Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
      Fig 28: Locating Blower Motor Connectors And Fixing Clip
      G11938433Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
      Fig 29: Locating Temperature Control Actuator Connector And Duct Sensor Connector
      G11938434Courtesy of KIA MOTORS AMERICA, INC.
    7. Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
      Fig 30: Locating Mode Control Actuator Connectors And Fixing Clip
      G11938435Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
    Fig 31: Locating VESS Unit Mounting Screw And Fixing Clip
    G11938436Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the mounting clips (A).
    Fig 32: Locating Mounting Clips
    G11938437Courtesy of KIA MOTORS AMERICA, INC.
    Fig 33: Locating Mounting Clip
    G11938438Courtesy of KIA MOTORS AMERICA, INC.
  32. Loosen the heater and blower unit mounting bolts (A).
    Fig 34: Locating Heater And Blower Unit Mounting Bolts
    G11938439Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
    Fig 35: Locating Heater And Blower Unit Or Crash Pad With Mounting Nuts
    G11938440Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the air duct (A) after loosening the mounting screw.
    Fig 36: Locating Air Duct
    G11938441Courtesy of KIA MOTORS AMERICA, INC.
  35. Disconnect the connector (B).

    And then remove the high voltage line guide (A) after loosening the mounting screws.

    Fig 37: Locating High Voltage Line Guide And Connector With Mounting Screws
    G11938442Courtesy of KIA MOTORS AMERICA, INC.
  36. Disconnect the high voltage PTC heater unit connector (A).
    Fig 38: Locating High Voltage PTC Heater Unit Connector
    G11938443Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
    Fig 39: Locating High Voltage PTC Heater Unit With Mounting Screws
    G11938444Courtesy of KIA MOTORS AMERICA, INC.
  38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
    Fig 40: Removing High Voltage PTC Heater Core
    G11938445Courtesy of KIA MOTORS AMERICA, INC.
  39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
    Fig 41: Locating Blower Unit, Heater Unit And Mounting Screws
    G11938446Courtesy of KIA MOTORS AMERICA, INC.
  40. Install in the reverse order of removal.
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