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Home >> Hyundai >> 2015 >> Sonata Eco >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 91 (Hybrid Control System (HEV)) >> HPCU (Hybrid Power Control Unit) >> Repair Procedures >> Removal

Repair Procedures: Removal

WARNING: This page is about a different variant/trim than selected.
WARNING: This hybrid system uses a DC 270V voltage system. Be sure to follow safety instructions below. Failure to follow safety instructions may result in serious injury or electrocution (Refer to "SAFETY PRECAUTION ").
  1. Shut off the High Voltage circuit (Refer to "HIGH VOLTAGE SHUTOFF PROCEDURE ).
  2. Drain the coolant of the hybrid motor cooling system and remove the reservoir installed on the HPCU (Refer to "HYBRID MOTOR COOLING SYSTEM - SONATA HEV article).
  3. Remove the air cleaner assembly and duct (Refer to "ENGINE INTAKE & EXHAUST SYSTEM - SONATA HEV article).
  4. Disconnect the coolant inlet hose (A) and outlet hose (B).
  5. Remove the HPCU protector (C).
    Fig 1: Identifying HPCU Protector, Coolant Inlet And Outlet Hose
    G10590654Courtesy of HYUNDAI MOTOR AMERICA
  6. Disconnect the power cable (A) from the HPCU.
    1. Pull the lever (B) in the direction of the arrow shown in illustration with the hook (C) pressed.
    2. Press the lever (D), and then pull the power cable connector.
    Fig 2: Identifying Power Cable Of HPCU
    G10590655Courtesy of HYUNDAI MOTOR AMERICA
    Fig 3: Hook & Levers
    G10590656Courtesy of HYUNDAI MOTOR AMERICA
  7. Disconnect the motor power cable (A).
    1. Pull the lever (B), and then pull the connector by rotating the lever (C).
  8. Disconnect the HSG power cable (D).
    1. Pull the lever (E), and then pull the connector by rotating the lever (F).
    Fig 4: Motor Power Cable, Levers & HSG Power Cable
    G10590657Courtesy of HYUNDAI MOTOR AMERICA
  9. Disconnect the electric A/C compressor power cable (A).
    1. Pull the lever (B) in the direction of the arrow shown in illustration.
    2. Press the hook (C), and then pull the motor power cable connector.
  10. Disconnect the MCU connector (D).
    Fig 5: Power Cable, Lever, Hook & MCU Connector
    G10590658Courtesy of HYUNDAI MOTOR AMERICA
  11. Disconnect the HCU connector (A) and LDC connector (B).
  12. Disconnect the LDC power outlet cable (C) and ground cable (D).
    Fig 6: Identifying HCU Connector, LDC Connector, LDC Power Outlet Cable And Ground Cable
    G10590659Courtesy of HYUNDAI MOTOR AMERICA
  13. Remove the installation bolts (A), and then remove the HPCU from the vehicle.
    Fig 7: Identifying HPCU Installation Bolts
    G10590660Courtesy of HYUNDAI MOTOR AMERICA
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