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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2015 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 "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 "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
  4. Remove the cowl top cover.

    (Refer to "COWL TOP COVER ")

  5. Remove the pipe (A) after loosening the mounting bolts.
    Fig 1: Remove Pipe
    G10745120Courtesy 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: Remove Expansion Valve
    G10745121Courtesy 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: Cowl Cross Member Mounting Bolts
    G10745122Courtesy 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 "STEERING WHEEL ")

  17. Remove the multifunction switch.

    (Refer to "MULTIFUNCTION SWITCH ")

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

    (Refer to Steering System - "STEERING COLUMN AND SHAFT ")

  19. Remove the rear airduct assembly (A).

    [LH] 

    1. Remove the accelerator pedal fixing cap (A).
      Fig 4: Accelerator Pedal Fixing Cap
      G10745123Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      Fig 5: Accelerator Pedal
      G10745124Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 6: Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G10745125Courtesy 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: Rear Air Duct Assembly
      G10745126Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 8: Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G10745127Courtesy of KIA MOTORS AMERICA, INC.
    2. Bend the front floor carpet (A) backwards.
      Fig 9: Front Floor Carpet
      G10745128Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the rear air duct assembly (A) after loosening the mounting nut.
      Fig 10: Rear Air Duct Assembly
      G10745129Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the shift lever assembly.

    (Refer to "SHIFT LEVER ASSEMBLY REMOVAL ")

  21. Disconnect the airbag control module (SRSCM) connector (A).
    Fig 11: Airbag Control Module Connector
    G10745130Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    Fig 12: Cowl Cross Bar Center Bracket
    G10745131Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    Fig 13: Passenger Compartment Junction Box Connectors
    G10745132Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    Fig 14: Passenger Compartment Junction Box Mounting Clips
    G10745133Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's] 

    Fig 15: Multi Box Connectors (Driver)
    G10745134Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 16: Multi Box Connectors (Passenger)
    G10745135Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    Fig 17: Front Pillar Connector And Mounting Clips (Driver)
    G10745136Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 18: Front Pillar Connector And Mounting Clips (Passenger)
    G10745137Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    Fig 19: Drain Hose
    G10745138Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    Fig 20: High Voltage PTC Heater Cable
    G10745139Courtesy 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
      G10745140Courtesy 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: Press Locker Pin Using Flat Driver
      G10745141Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    Fig 23: Main Crash Pad And Cowl Cross Bar Assembly
    G10745142Courtesy 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: High Voltage Heater Ground
      G10745143Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
      Fig 25: Fixing Clip And Intake Actuator Connector
      G10745144Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the fixing clip (B) after disconnecting the blower unit connector (A).
      Fig 26: Fix Clip And Blower Unit Connector
      G10745145Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
      Fig 27: Fix Clip And PWM Unit Connector
      G10745146Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
      Fig 28: Fixing Clip And Blower Motor Connectors
      G10745147Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
      Fig 29: Temperature Control Actuator Connector And Duct Sensor Connector
      G10745148Courtesy of KIA MOTORS AMERICA, INC.
    7. Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
      Fig 30: Fix Clip And Mode Control Actuator Connectors
      G10745149Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
      Fig 31: Loosen VESS Unit Mounting Screw
      G10745150Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the mounting clips (A).
    Fig 32: Mounting Clips (1 Of 2)
    G10745151Courtesy of KIA MOTORS AMERICA, INC.
    Fig 33: Mounting Clips (2 Of 2)
    G10745152Courtesy of KIA MOTORS AMERICA, INC.
  32. Loosen the heater and blower unit mounting bolts (A).
    Fig 34: Heater And Blower Unit Mounting Bolts
    G10745153Courtesy 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: Heater And Blower Unit
    G10745154Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the air duct (A) after loosening the mounting screw.
    Fig 36: Air Duct
    G10745155Courtesy 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: High Voltage Line Guide
    G10745156Courtesy of KIA MOTORS AMERICA, INC.
  36. Disconnect the high voltage PTC heater unit connector (A).
    Fig 38: High Voltage PTC Heater Unit Connector
    G10745157Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
    Fig 39: Remove High Voltage PTC Heater Unit
    G10745158Courtesy of KIA MOTORS AMERICA, INC.
  38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
    Fig 40: Remove High Voltage PTC Heater Core
    G10745159Courtesy of KIA MOTORS AMERICA, INC.
  39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
    Fig 41: Remove Blower Unit From Heater Unit
    G10745160Courtesy of KIA MOTORS AMERICA, INC.
  40. Install in the reverse order of removal.
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