Repair procedures

Removal

WARNING:
The hybrid system uses DC 270V high voltage. So, be sure to follow safety instructions below. Otherwise, there may be a serious injury or electrocution .

1. Shut off the High Voltage circuit .
2. Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU .
3. Remove the air cleaner assembly and duct .
4. Disconnect the coolant inlet hose (A) and outlet hose (B).
5. Remove the HPCU protector (C).




6. Disconnect the power cable (A) from the HPCU.
(1) Pull the lever (B) in the direction of the arrow with the hook (C) pressed.
(2) Press the lever (D), and then pull the power cable connector.








7. Disconnect the motor power cable (A).
(1) Pull the lever (B), and then pull the connector by rotating the lever (C).
8. Disconnect the HSG power cable (D).
(1) Pull the lever (E) in the direction of the arrow.
(2) Press the hook (F), and then pull the motor power cable connector.




9. Disconnect the electric A/C compressor power cable (A).
(1) Pull the lever (B) in the direction of the arrow.
(2) Press the hook (C), and then pull the motor power cable connector.
10. Disconnect the MCU connector (D).




11. Disconnect the HCU connector (A) and LDC connector (B).
12. Disconnect the LDC power outlet cable (C) and ground cable (D).




13. Remove the installation bolts (A), and then remove the HPCU from the vehicle.






Installation

WARNING:
The hybrid system uses DC 270V high voltage. So, be sure to follow safety instructions below. Otherwise, there may be a serious injury or electrocution .

1. Installation is reverse of removal.

HPCU installation bolt:
19.6 - 29.4 N.m (2.0 - 3.0 kgf.m, 14.5 - 21.7 lb-ft)
LDC power outlet cable tightening bolt:
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
LDC ground cable tightening bolt:
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)