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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2015 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 PROCEDURE "High Voltage Shut-off Procedure"). 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 Lubricants EV Battery System - "High Voltage Shut-off Procedure")
  4. Remove the cowl top cover.

    (Refer to COWL TOP COVER Body - "Cowl Top Cover")

  5. Remove the pipe (A) after loosening the mounting bolts.
    Fig 1: Pipe Mounting Bolts
    G10745077Courtesy 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)

    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).
    Fig 2: Cowl Cross Member Mounting Bolts
    G10745078Courtesy 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 WHEEL Steering System - "Steering Wheel")

  17. Remove the multifunction switch.

    (Refer to MULTIFUNCTION SWITCH 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).
      Fig 3: Accelerator Pedal Fixing Cap
      G10745079Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      Fig 4: Accelerator Pedal Mounting Bolt
      G10745080Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 5: Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G10745081Courtesy 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.
      Fig 6: Rear Air Duct Assembly And Mounting Nut
      G10745082Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 7: Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G10745083Courtesy of KIA MOTORS AMERICA, INC.
    2. Bend the front floor carpet (A) backwards.
      Fig 8: Front Floor Carpet
      G10745084Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the rear air duct assembly (A) after loosening the mounting nut.
      Fig 9: Rear Air Duct Assembly And Mounting Nut
      G10745085Courtesy 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).
    Fig 10: Airbag Control Module (SRSCM) Connector
    G10745086Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    Fig 11: Cowl Cross Bar Center Bracket Mounting Bolts And Nuts
    G10745087Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    Fig 12: Passenger Compartment Junction Box Connectors
    G10745088Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    Fig 13: Passenger Compartment Junction Box Mounting Clips
    G10745089Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's] 

    Fig 14: Multi Box Connectors (Driver)
    G10745090Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 15: Multi Box Connectors (Passenger)
    G10745091Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    Fig 16: Front Pillar Connector And Mounting Clips (Driver)
    G10745092Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 17: Front Pillar Connector And Mounting Clips (Passenger)
    G10745093Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    Fig 18: Drain Hose
    G10745094Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    Fig 19: High Voltage PTC Heater Cable
    G10745095Courtesy 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.
      Fig 20: Pulling PTC Heater Cable Locker Pin
      G10745096Courtesy of KIA MOTORS AMERICA, INC.
    2. While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.
      Fig 21: Pulling Out PTC Heater Cable Connector Using Flat Driver
      G10745097Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    Fig 22: Loosening Main Crash Pad And Cowl Cross Bar Assembly Mounting Bolts
    G10745098Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the interior condenser cover (A) after loosening the mounting screws.
    Fig 23: Loosening Interior Condenser Cover Mounting Screws
    G10745099Courtesy of KIA MOTORS AMERICA, INC.
  31. Remove the interior condenser (A) in the direction of the arrow. Since the electric compressor uses high-voltage, POE oil with high resistivity should be used.
    Fig 24: Removing Interior Condenser
    G10745100Courtesy of KIA MOTORS AMERICA, INC.
  32. Install in the reverse order of removal.
    CAUTION:
    • Do not use the same A/C recovery/charging station as conventional belt-driven compressors.
    • 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.
    • 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.
    • If you're installing a new condenser, 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.
    • Be careful not to damage the radiator and condenser fins when installing the condenser.
    • Be sure to install the lower mount cushions of condenser securely into the holes.
    • Charge the system, and test its performance.
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