Kia Soul EV: Heater / Heater Unit Repair procedures

Kia Soul EV (PS EV) 2015-2020 Service Manual / Heating,Ventilation, Air Conditioning / Heater / Heater Unit Repair procedures

Replacement

•	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.

•	Put on gloves to protect your hands.

•	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.

Recover the refrigerant with a recovery/ recycling/ charging station.

•	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.

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 Ib-ft)

•	Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

7.	Loosen the cowl cross member mounting bolts (A).

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).

(2)	Remove the accelerator pedal (A) after loosening the mounting bolt.

(3)	Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).

(4)	Bend the front floor carpet backwards.

(5)	Remove the rear air duct assembly (A) after loosening the mounting nut. [RH]

(6)	Remove the floor carpet fixing clip (A) and the floor wire fixing clip (B).

(7)	Bend the front floor carpet (A) backwards.

(8)	Remove the rear air duct assembly (A) after loosening the mounting nut.

20.	Remove the shift lever assembly. (Refer to Automatic Transaxle System - "Shift Lever")

21.	Disconnect the airbag control module (SRSCM) connector (A).

22.	After loosening the mounting bolts and nuts, remove the cowl cross bar center bracket (A).

23.	Disconnect the passenger compartment junction box connectors (A).

24.	Remove the passenger compartment junction box mounting clips (A).

25.	Disconnect the multi box connectors (A). [Driver''s] [Passenger''s]

26.	Disconnect the connector (A) and the mounting clips (B) in the front pillar. [Driver''s] [Passenger''s]

27.	Remove the drain hose (A).

28.

Disconnect the high voltage PTC heater cable (A).

•	How to press the high voltage PTC heater cable locker pin

1)	Pull the locker pin (A) in the direction of the arrow.

2)	While pressing the locker pin using a flat driver (A) on the hole (B), pull out the connector.

29.	After loosening the bolts, remove the main crash pad and cowl cross bar assembly (A) altogether.

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).

(2)	Remove the fixing clip (B) after disconnecting the intake actuator connector (A).

(3)	Remove the fixing clip (B) after disconnecting the blower unit connector (A).

(4)	Remove the fixing clip (B) after disconnecting the PWM unit connector (A).

(5)	Remove the fixing clip (B) after disconnecting the blower motor connectors (A).

(6)	Disconnect the temperature control actuator connector (A) and duct sensor connector (B).

(7)	Remove the fixing clip (B) after disconnecting the mode control actuator conenctors (A).

(8)	Remove the fixing clips (B) after loosening the VESS unit mounting screw (A).

31.	Remove the mounting clips (A).

32.	Loosen the heater and blower unit mounting bolts (A).

33.	Remove the heater and blower unit (A) from the crash pad (B) after loosening the mounting nuts.

34.	Remove the air duct (A) after loosening the mounting screw.

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

36.	Disconnect the high voltage PTC heater unit connector (A).

37.	Remove the high voltage PTC heater unit (A) after loosening the mounting screws.

38.	Remove the high voltage PTC heater core (A) after loosening the mounting screws.

39.	Separate the blower unit (A) from the heater unit (B) after loosening the mounting screws (C).

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.tIf 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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