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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2019 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 PROCEDURES "). 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 Body - "COWL TOP COVER ")

  5. Remove the pipe (A) after loosening the 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)

    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).
    G12822841Courtesy 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 System - "STEERING WHEEL ")

  17. Remove the multifunction switch.

    (Refer to Body Electrical System - "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).
      G11938409Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      G12822843Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      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.
      G11938412Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      G11938413Courtesy of KIA MOTORS AMERICA, INC.
    2. Bend the front floor carpet (A) backwards.
      G11938414Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the rear air duct assembly (A) after loosening the 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).
    G12822849Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    G11938417Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    G11938418Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    G11938419Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's] 

    G12822853Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G11938421Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    G12822855Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    G12822856Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    G11938424Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    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.
      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.
      G11938427Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    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).
      G11938429Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
      G11938430Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the fixing clip (B) after disconnecting the blower unit connector (A).
      G11938431Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
      G11938432Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
      G11938433Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
      G11938434Courtesy of KIA MOTORS AMERICA, INC.
    7. Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
      G11938435Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
      G11938436Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the mounting clips (A).
    G11938437Courtesy of KIA MOTORS AMERICA, INC.
    G11938438Courtesy of KIA MOTORS AMERICA, INC.
  32. Loosen the heater and blower unit mounting bolts (A).
    G11938439Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
    G11938440Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the air duct (A) after loosening the mounting screw.
    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.

    G11938442Courtesy of KIA MOTORS AMERICA, INC.
  36. Disconnect the high voltage PTC heater unit connector (A).
    G11938443Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
    G11938444Courtesy of KIA MOTORS AMERICA, INC.
  38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
    G11938445Courtesy of KIA MOTORS AMERICA, INC.
  39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
    G11938446Courtesy of KIA MOTORS AMERICA, INC.
  40. Install in the reverse order of removal.
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