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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.
    G11938274Courtesy 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)

    G11938275Courtesy of KIA MOTORS AMERICA, INC.
    CAUTION:
    • Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.
  7. Loosen the cowl cross member mounting bolts (A).
    G12822709Courtesy 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).
      G11938277Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      G11938278Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      G11938279Courtesy 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.
      G11938280Courtesy of KIA MOTORS AMERICA, INC.

      [RH] 

    6. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      G11938281Courtesy of KIA MOTORS AMERICA, INC.
    7. Bend the front floor carpet (A) backwards.
      G11938282Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the rear air duct assembly (A) after loosening the mounting nut.
    G11938283Courtesy 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).
    G12822717Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    G11938285Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    G11938286Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    G11938287Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's]

    G11938288Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's]

    G11938289Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's]

    G12822723Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's]

    G12822724Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    G11938292Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    G11938293Courtesy of KIA MOTORS AMERICA, INC.

    information 

    • How to press the high voltage PTC heater cable locker pin
      1. Pull the locker pin (A) in the direction of the arrow.
        G11938294Courtesy of KIA MOTORS AMERICA, INC.
      2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
        G11938295Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    G12822729Courtesy 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).
      G11938297Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the fixing clip (B) after disconnecting the intake actuator connector (A).
      G11938298Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the fixing clip (B) after disconnecting the blower unit connector (A).
      G11938299Courtesy of KIA MOTORS AMERICA, INC.
    4. Remove the fixing clip (B) after disconnecting the PWM unit connector (A).
      G11938300Courtesy of KIA MOTORS AMERICA, INC.
    5. Remove the fixing clip (B) after disconnecting the blower motor connectors (A).
      G11938301Courtesy of KIA MOTORS AMERICA, INC.
    6. Disconnect the temperature control actuator connector (A) and duct sensor connector (B).
      G11938302Courtesy of KIA MOTORS AMERICA, INC.
    7. Remove the fixing clip (B) after disconnecting the mode control actuator connectors (A).
      G11938303Courtesy of KIA MOTORS AMERICA, INC.
    8. Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).
      G11938304Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the mounting clips (A).
    G11938305Courtesy of KIA MOTORS AMERICA, INC.
    G11938306Courtesy of KIA MOTORS AMERICA, INC.
  32. Loosen the heater and blower unit mounting bolts (A).
    G11938307Courtesy of KIA MOTORS AMERICA, INC.
  33. Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.
    G12822741Courtesy of KIA MOTORS AMERICA, INC.
  34. Remove the air duct (A) after loosening the mounting screw.
    G11938309Courtesy of KIA MOTORS AMERICA, INC.
  35. Disconnect the connector (B).

    And then remove the high voltage line guide (A) after loosening the mounting screws.

    G11938310Courtesy of KIA MOTORS AMERICA, INC.
  36. Disconnect the high voltage PTC heater unit connector (A).
    G11938311Courtesy of KIA MOTORS AMERICA, INC.
  37. Remove the high voltage PTC heater unit (A) after loosening the mounting screws.
    G11938312Courtesy of KIA MOTORS AMERICA, INC.
  38. Remove the high voltage PTC heater core (A) after loosening the mounting screws.
    G11938313Courtesy of KIA MOTORS AMERICA, INC.
  39. Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).
    G11938314Courtesy of KIA MOTORS AMERICA, INC.
  40. Install in the reverse order of removal and note the followings:
    • If you're installing a new evaporator, add refrigerant oil. (POE OIL)
    • Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
    • Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
    • Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately
    • Apply sealant to the grommets.
    • Make sure that there is no air leakage.
    • Charge the system and test its performance.
    • Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
    • Refill the cooling system with engine coolanSince 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.
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