Hybrid Power Control Unit (HPCU)

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

Shut off the high voltage circuit.
(Refer to Hybrid Control System - "HIGH VOLTAGE SHUT-OFF PROCEDURE ")
Remove the air cleaner assembly and air duct.
(Refer to Engine Mechanical System - "AIR CLEANER ")
Remove the ECM & TCM bracket assembly.
(Refer to Engine Control/Fuel System - "ENGINE CONTROL MODULE ")
Drain the coolant of hybrid motor cooling system.
(Refer to Hybrid Motor Cooling System - "COOLANT ")
Remove the HPCU protector (A) after loosening the mounting bolts.

Fig 1: Locating HPCU Protector Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the motor power cable connector (A) and HSG power cable connector (B).

Fig 2: Locating Motor Power Cable Connector And HSG Power Cable Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the power cable (A) [↔ High voltage battery system assembly] and power cable (B) [↔ HSG & Electric A/C compressor].

Fig 3: Locating Power Cable
Courtesy of KIA MOTORS AMERICA, INC.

Information

Remove the inverter power cable in the following order.

Fig 4: Removing Inverter Power Cable
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the HCU & inverter (MCU) connector (A).

Fig 5: Locating HCU & Inverter (MCU) Connector
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the coolant outlet hose & pipe (A) after loosening the mounting bolt.

Fig 6: Locating Coolant Outlet Hose & Pipe Mounting Bolt
Courtesy of KIA MOTORS AMERICA, INC.
Disconnect the LDC power output cable (A) and LDC ground (-) cable (C) after loosening the mounting bolt and nut.
LDC Power (12V) Output Cable Mounting Nut:

10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 7.9 - 10.1 lb.ft)

LDC ground cable mounting bolt:

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

Fig 7: Locating LDC Power Output Cable And LDC Ground (-) Cable
Courtesy of KIA MOTORS AMERICA, INC.
Remove the HPCU (B) after loosening the mounting bolts.
HPCU Mounting Bolt:

21.6 - 23.5 N.m (2.2 - 2.4 kgf.m, 15.9 - 17.4 lb.ft)

Fig 8: Locating HPCU Mounting Bolts
Courtesy of KIA MOTORS AMERICA, INC.
Remove the coolant hose & pipe (A) from the HPCU.
Remove the reservoir (B) after loosening the mounting bolts.
Reservoir Mounting Bolt:

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

Fig 9: Removing Coolant Hose & Pipe From HPCU (1 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.

Fig 10: Removing Coolant Hose & Pipe From HPCU (2 Of 2)
Courtesy of KIA MOTORS AMERICA, INC.