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Repair Procedures: Replacement

WARNING: This page is about a different car, the 2016 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 ").

    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 COWL TOP COVER "Cowl Top Cover")

  5. Remove the pipe (A) after loosening the mounting bolts.
    Fig 1: Locate Pipe With Mounting Bolts
    G11938364Courtesy 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: Locate Cowl Cross Member Mounting Bolts
    G11938365Courtesy 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 the appropriate service information. Steering System - "Steering Wheel")

  17. Remove the multifunction switch.

    (Refer to "MULTIFUNCTION SWITCH ASSEMBLY REMOVAL " "Multifunction Switch")

  18. Lower the steering column after loosening the mounting bolts.

    (Refer to the appropriate service information. Steering System - "Steering Column and Shaft")

  19. Remove the rear airduct assembly (A).

    [LH] 

    1. Remove the accelerator pedal fixing cap (A).
      Fig 3: Locate Accelerator Pedal Fixing Cap
      G11938366Courtesy of KIA MOTORS AMERICA, INC.
    2. Remove the accelerator pedal (A) after loosening the mounting bolt.
      Fig 4: Locate Accelerator Pedal With Mounting Bolt
      G11938367Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 5: Locate Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G11938368Courtesy 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: Locate Rear Air Duct Assembly With Mounting Nut
    G11938369Courtesy of KIA MOTORS AMERICA, INC.

    [RH] 

    1. Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).
      Fig 7: Locate Floor Carpet Fixing Clip And Floor Wire Fixing Clip
      G11938370Courtesy of KIA MOTORS AMERICA, INC.
    2. Bend the front floor carpet (A) backwards.
      Fig 8: Locating Front Floor Carpet
      G11938371Courtesy of KIA MOTORS AMERICA, INC.
    3. Remove the rear air duct assembly (A) after loosening the mounting nut.
    Fig 9: Locate Rear Air Duct Assembly With Mounting Nut
    G11938372Courtesy of KIA MOTORS AMERICA, INC.
  20. Remove the shift lever assembly.

    (Refer to "SHIFT LEVER REMOVAL " "Shift Lever")

  21. Disconnect the airbag control module (SRSCM) connector (A).
    Fig 10: Locate Airbag Control Module Connector
    G11938373Courtesy of KIA MOTORS AMERICA, INC.
  22. After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).
    Fig 11: Locate Cowl Cross Bar Center Bracket With Mounting Bolts And Nuts
    G11938374Courtesy of KIA MOTORS AMERICA, INC.
  23. Disconnect the passenger compartment junction box connectors (A).
    Fig 12: Locate Passenger Compartment Junction Box Connectors
    G11938375Courtesy of KIA MOTORS AMERICA, INC.
  24. Remove the passenger compartment junction box mounting clips (A).
    Fig 13: Locate Passenger Compartment Junction Box Mounting Clips
    G11938376Courtesy of KIA MOTORS AMERICA, INC.
  25. Disconnect the multi box connectors (A).

    [Driver's] 

    Fig 14: Locate Multi Box Connectors - Driver'S
    G11938377Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 15: Locate Multi Box Connectors - Passenger'S
    G11938378Courtesy of KIA MOTORS AMERICA, INC.
  26. Disconnect the connector (A) and the mounting clips (B) in the front pillar.

    [Driver's] 

    Fig 16: Locate Front Pillar Connector And Mounting Clips - Driver'S
    G11938379Courtesy of KIA MOTORS AMERICA, INC.

    [Passenger's] 

    Fig 17: Locate Front Pillar Connector And Mounting Clips - Passenger'S
    G11938380Courtesy of KIA MOTORS AMERICA, INC.
  27. Remove the drain hose (A).
    Fig 18: Removing Drain Hose
    G11938381Courtesy of KIA MOTORS AMERICA, INC.
  28. Disconnect the high voltage PTC heater cable (A).
    Fig 19: Locate High Voltage PTC Heater Cable
    G11938382Courtesy 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: Pull Locker Pin
      G11938383Courtesy 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: Press Locker Pin Using Flat Driver On Hole
    G11938384Courtesy of KIA MOTORS AMERICA, INC.
  29. After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.
    Fig 22: Locate Main Crash Pad And Cowl Cross Bar Assembly With Bolts
    G11938385Courtesy of KIA MOTORS AMERICA, INC.
  30. Remove the interior condenser cover (A) after loosening the mounting screws.
    Fig 23: Locate Interior Condenser Cover With Mounting Screws
    G11938386Courtesy 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: Remove Interior Condenser
    G11938387Courtesy 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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