2018 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).
    G12793532Courtesy of HYUNDAI MOTOR AMERICA
  3. Lightly tighten the manual control lever mounting nut (B) after installing the manual control lever (A).
    G12793533Courtesy 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).
    G12793534Courtesy 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)

    G12793535Courtesy 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)

    G12793536Courtesy 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).
    G12793537Courtesy of HYUNDAI MOTOR AMERICA
  11. Install the HPCU (Refer to "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)

    G12793538Courtesy 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.
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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.