Repair Procedures: Replacement

CAUTION:

Put on gloves to prevent hand injuries.

NOTE:

When removing with a flat-tip screwdriver or remover, wrap protective tape around the tools to prevent damage to components.
When removing the interior trim pieces, use a plastic panel removal tool not to damage the surface.
Take care not to bend or scratch the trim and panels.

Disconnect the negative(-) battery terminal.
Recover the refrigerant with a recovery/recycling/charging station.
When the engine is cool, drain the engine coolant from the radiator. (Refer to Engine Mechanical System - "Coolant ")
Remove the cowl top cover. (Refer to COWL TOP COVER - SONATA PHEV )
Disconnect the expansion valve from the evaporator core. (Refer to Heating, Ventilation And Air Conditioning - "Heater Unit ")
Disconnect the inlet and outlet heater hoses from the heater unit. (Refer to Heating, Ventilation And Air Conditioning - "Heater Unit ")
Loosen the engine room cowl cross bar assembly mounting bolts.

Fig 1: Loosening Engine Room Cowl Cross Bar Assembly Mounting Bolts
Courtesy of HYUNDAI MOTOR AMERICA
Remove both sides of front seat assembly. (Refer to Front Seat - "Front Seat Assembly ")
Remove the main crash pad assembly. (Refer to Crash Pad - "Main Crash Pad Assembly ")
Disconnect the steering column connectors. (Refer to STEERING WHEEL - SONATA PHEV )
Loosen the mounting nuts and through bolts in the frontal area and lower the steering column. (Refer to STEERING WHEEL - SONATA PHEV )
Remove the shift lever assembly. (Refer to Automatic Transaxle System - "Shift lever ")
Disconnect the airbag control module (SRSCM) connector (A).

Fig 2: Locating Airbag Control Module (SRSCM) Connector
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the connector (A) and the mounting wiring fasteners in the front pillar.
[Driver's]

Fig 3: Locating Connector And Mounting Wiring Fasteners In Front Pillar (Driver)
Courtesy of HYUNDAI MOTOR AMERICA

[Passenger's]

Fig 4: Locating Connector And Mounting Wiring Fasteners In Front Pillar (Passenger)
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the passenger compartment junction box connectors (A).

Fig 5: Disconnecting Passenger Compartment Junction Box Connectors
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the multi box connectors (A).
[Driver's]

Fig 6: Locating Multi Box Connectors (Driver)
Courtesy of HYUNDAI MOTOR AMERICA

[Passenger's]

Fig 7: Locating Multi Box Connectors (Passenger)
Courtesy of HYUNDAI MOTOR AMERICA
Remove the drain hose (A).

Fig 8: Locating Drain Hose
Courtesy of HYUNDAI MOTOR AMERICA
After loosening the nuts and bolts, remove the cowl cross bar and heater & blower unit (A) together.

Fig 9: Locating Cowl Cross Bar And Heater & Blower Unit
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the heater & blower unit connectors.
1. Disconnect the blower motor connector (A) and then remove the wiring mounting clips.
  
  Fig 10: Locating Wiring Mounting Clips
  Courtesy of HYUNDAI MOTOR AMERICA
2. Disconnect the temperature control actuator (A), mode control actuator (B) connectors and then remove the wiring mounting clips.
  
  Fig 11: Disconnecting Temperature Control Actuator
  Courtesy of HYUNDAI MOTOR AMERICA
3. Disconnect the auto defogging sensor connector (A) and then remove the wiring mounting clips.
  
  Fig 12: Disconnecting Auto Defogging Sensor Connector
  Courtesy of HYUNDAI MOTOR AMERICA
4. Disconnect the intake actuator (A), cluster ionizer connector (B), power mosfet (C) connectors and then remove the wiring mounting clips.
  
  Fig 13: Disconnecting Intake Actuator, Cluster Ionizer Connector, Power Mosfet
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the heater and blower unit (A) from the cowl cross bar (B) after loosening the mounting nuts.

Fig 14: Locating Heater And Blower Unit From Cowl Cross Bar
Courtesy of HYUNDAI MOTOR AMERICA
Install in the reverse order of removal.
Information
- Make sure the crash pad fits onto the guide pins correctly.
- Before tightening the bolts, make sure the crash pad wire harnesses are not pinched.
- Make sure the connectors are plugged in properly, and the antenna lead is connected properly.
- Enter the anti- theft code for the radio, then enter the customer's radio station presets.
- Make sure that each of the assembly components operates properly.
- Replace any damaged clips.