2017 Hyundai Sonata Plug-In HybridFACTORY OEM SERVICE PROCEDURE

Repair Procedures: Installation

  1. Check that the shift lever is placed in the "N" position
  2. Lightly tighten the inhibitor switch mounting bolts (A) after installing the inhibitor switch (B).
    Fig 1: Locating Inhibitor Switch Mounting Bolts
    G11631357Courtesy of HYUNDAI MOTOR AMERICA
  3. Lightly tighten the manual control lever mounting nut (B) after installing the manual control lever (A).
    Fig 2: Locating Inhibitor Switch Manual Control Lever Mounting Nut
    G11631358Courtesy of HYUNDAI MOTOR AMERICA
  4. Align the hole (A) in the manual control lever with the "N" position hole (B) of the inhibitor switch and then insert the inhibitor switch guide pin (SST No.:09480-A3800).
    Fig 3: Inserting Inhibitor Switch Guide Pin
    G11631359Courtesy of HYUNDAI MOTOR AMERICA
  5. Tighten the nut (A) and bolts (B) with the specified torque.

    Tightening torque: 

    A: 17.7 ~ 24.5 N.m (1.8 ~ 2.5 kgf.m, 13.0 ~ 18.1 lb-ft)

    B: 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

    Fig 4: Inhibitor Switch Nuts Location
    G11631360Courtesy of HYUNDAI MOTOR AMERICA
  6. Lightly tighten the nut (B) after connected the shift cable (C) in the manual control lever (D).
  7. Push shift cable (C) lightly to "F" direction shown to eliminate free play of shift cable.
  8. Tighten the nut (B) with the specified torque.

    Tightening torque: 

    9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

    Fig 5: Pushing Shift Cable
    G11631361Courtesy of HYUNDAI MOTOR AMERICA
  9. Remove the inhibitor switch guide pin (SST No.: 09480-A3800) from the hole.
  10. Connect the inhibitor switch connector (A).
    Fig 6: Connecting Inhibitor Switch Connector
    G11631362Courtesy of HYUNDAI MOTOR AMERICA
  11. Install the HPCU (Refer to Hybrid Control System-"Hybrid Power Control Unit ")
  12. Install the Hybrid Power Control Unit (HPCU) tray (A).

    Tightening torque: 

    8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

    Fig 7: Installing Hybrid Power Control Unit (HPCU) Tray
    G11631363Courtesy of HYUNDAI MOTOR AMERICA
  13. Connect the battery negative (-) cable.
  14. Connect the high voltage.
  15. Check that operating surely at each range of the inhibitor switch corresponding to each position of shift lever.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.