Service Procedure
Service Procedure:WARNING
This repair must be conducted only by Kia Hybrid trained technicians.
Be sure to remove the hybrid battery safety plug before performing this repair, and keep the plug in your possession until complete. If not, electric discharge injury may result from high-voltage current.
Follow safety procedures and use personal protective equipment defined by KGIS (Service Info > Shop Manual > General Information > General Safety Information and Cautions).
1. Record the customer's radio station presets before disconnecting battery.
Open the trunk and remove the hybrid battery safety plug (located on the right-hand side of the trunk) by pressing up on the black latch (A) and then pulling out the orange lever. Keep the hybrid battery safety plug in your possession until the repair is complete.
Disconnect the 12V auxiliary battery negative cable.
2. Open the hood and proceed to remove air duct assembly, air cleaner, and hose assembly to gain access to DC input and electric A/C compressor output connectors.
3. Remove the air duct assembly by removing the two (2) fasteners as indicated by the circles.
4. Remove the air cleaner & hose assembly.
5. Locate the DC input connector and electric A/C compressor output connector that are connected to the HPCU (Hybrid Power Control Unit).
Electric A/C Compressor Output Connector Repair
6. Pull back the CPA (connector position assurance) tab.
7. With the housing lever pressed, disconnect the E-compressor output connector from the HPCU.
The photo above shows the E-compressor output connector disconnected.
8. Remove the tape from the corrugated tube end as shown in the photo.
9. Place a permanent mark on the No. 1 wire nearest the yellow CPA tab, as indicated in the photo, to prevent confusion when re-connecting the wire.
CAUTION
Make certain the connector top (side with yellow CPA tab) is facing upward as shown in the photo above to ensure that No. 1 wire (Top) is properly marked.
CAUTION
It is important to identify the wire location. If the positions of the wires are swapped when reinstalling into the new connector, then severe vehicle damage will occur.
10. Insert a small flat-head screwdriver or similar tool into the removal hole and pry out the two (2) connector rear holders (arrows indicate pry points). Discard old rear holders, they cannot be reused. Do not attempt to use Pin Release Tool for prying rear holders.
CAUTION
Be careful not to accidentally damage the cable with the screwdriver.
The rear holders and connector body may be damaged when prying out the rear holders. This is OK, as these original parts will be discarded.
11. Squeeze a small flat-head screwdriver between the shield contactors and the shield ring to loosen the tension of the shield contactors on each wire.
At this step, do not attempt to remove the wire from the connector.
CAUTION
Relief of the shield contactor tension is a key step to prevent cable damage during pin removal. Be careful not to damage the wire when relieving the contactor tension.
12. Insert the A/C Pin Release Tool and push it into the front pin holes of the connector.
Press the tool down firmly (B) while pulling out the wire from below the connector (C).
Repeat steps for the other wire terminal.
Discard the old connector body. It cannot be reused.
CAUTION
DO NOT use excessive force to pull the wire out as it may damage the cable, not enough tension was relieved from the shield connector, as indicated in the previous step.
13. Inspect E-compressor cable quality after removal of wire terminals.
CAUTION
Make sure cable is not damaged.
Check for:
- Wire damage.
- Terminal damage.
- Shield ring is not loose on wire.
- Braided metal wire is not exposed out of the shield ring.
- Yellow seal damage.
- If damage is found, then the cable assembly must be replaced.
14. Insert each terminal into the new E-compressor output connector.
1) Be sure to insert the No. 1 wire terminal that you marked, as indicated in step 9, into the connector nearest the yellow latch.
2) If incorrectly inserted, serious vehicle damage will occur when power is turned on.
3) Firmly insert the wire terminal until the confirmation "click" sound is heard.
4) Confirm that the wires cannot be pulled out after they are installed.
15. Install new connector rear holders into the connector until they lock into place.
16. Tape the corrugated tube and the wires using the insulating tape provided. Properly applied insulating tape is shown in the photo above.
17. Connect the E-compressor output connector to the HPCU.
CAUTION
1) Firmly connect the E-compressor output connector until confirmation "click" is heard.
2) Firmly push the CPA (connector position assurance) lever until a "click" is heard.
DC Input Connector Repair
18. With the key pressed, pull back the CPA (connector position assurance) tab.
19. With the housing lever pressed, disconnect the DC input connector from the HPCU.
20. The photo above shows the DC input connector disconnected.
21. Remove the tape from the corrugated tube end. If necessary, cut back the corrugated tube approximately 1 inch on each wire.
CAUTION
Be careful to cut only the corrugated tube, without damaging the wire insulation inside.
22. Place a permanent mark on the No. 1 wire nearest the yellow CPA tab, as indicated in the photo to prevent confusion when re-connecting the wire.
CAUTION
Make certain the connector top (side with yellow CPA tab) is facing upward as shown in the photo above to ensure that No. 1 wire (Top) is properly marked.
WARNING
It is important to identify the wire location. If the positions of the wires are swapped when reinstalling into the new connector, then severe vehicle damage will occur.
23. Insert a small flat-head screwdriver or similar tool into the removal hole and pry off the two (2) connectors rear holders. Discard the old rear holders, they cannot be reused.
Do not attempt to use Pin Release Tool for prying the rear holders.
CAUTION
Be careful not to accidentally damage the cable with the screwdriver.
The rear holders and connector body may be damaged when prying out the rear holders. This is OK, as these original parts will be discarded.
24. Squeeze a small flat head screwdriver between the shield contactors and the wire to loosen the tension of the shield contactors on each wire.
CAUTION
Relief of the shield contactor tension is a key step to prevent cable damage during pin removal. Be careful not to damage the wire when relieving the contactor tension.
25. With the DC Pin Release Tool pushed firmly into the front pin holes, pull the wire out from the connector.
Repeat for the other wire terminal.
Discard the old connector body. It cannot be reused.
CAUTION
DO NOT use excessive force to pull the wire out as it may damage the cable. If excessive effort is required, not enough tension was relieved from the shield contactor, as indicated in the previous step.
26. Inspect DC input cable quality after removal of wire terminals.
CAUTION
Make sure cable is not damaged.
Check for:
- Wire damage.
- Terminal damage.
- Shield ring is not loose on wire.
- Braided metal wire is not exposed out of the shield ring.
- Orange seal damage.
- If damage is found, then the cable assembly must be replaced.
27. Firmly grasp and insert each wire terminal into the new DC input connector.
CAUTION
1) Be sure to insert the No. 1 wire terminal that you marked using a permanent marker as indicated in step 24 into the connector with the yellow latch.
2) If incorrectly inserted, serious vehicle damage will occur when power is turned on.
3) Firmly insert the wire terminal until the confirmation "click" sound is heard.
4) Confirm that the wires cannot be pulled out after they are installed.
28. Install new connector rear holders into the connector until they lock into place.
29. Tape the corrugated tube using the insulating tape provided.
30. Connect the DC input connector to the HPCU.
CAUTION
1) Firmly connect the DC input connector until the confirmation "click" is heard.
2) Firmly push the CPA (connector position assurance) lever until a "click" sound is heard.
31. Re-install the air duct assembly and the air cleaner & hose assembly in the reverse order of removal.
Re-install the safety plug in the trunk
Reconnect the 12V auxiliary battery negative cable and reprogram radio station presets as recorded in step 1.
32. Use GDS to check for DTCs, clear DTCs as required.
Test drive vehicle to ensure proper operation.