Repair Procedures: Removal

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.

Remove the under cover. (Refer to Engine Mechanical System-"Engine Room Under cover ")
Drain the engine coolant. (Refer to Engine Mechanical System-"Coolant ")
Drain the coolant of motor cooling system. (Hybrid Motor System-"Coolant")
Remove the engine cover (A).
Remove the air cleaner assembly and air duct (B). (Refer to Engine Mechanical System-"Air cleaner ")
Remove the Hybrid Power Control Unit (HPCU) assembly (C). (Refer to Hybrid control system - "HPCU ")

Fig 1: Hybrid Power Control Unit (HPCU) Components Location
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the high voltage cable mounting clips (A) and bracket (B).

Fig 2: Locating High Voltage Cable Mounting Clips And Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Hybrid Power Control Unit (HPCU) tray (A).
Tightening torque:

8.8 ~ 13.7 N.m (0.9 ~ 1.4 kgf.m, 6.5 ~ 10.1 lb-ft)

Fig 3: Hybrid Power Control Unit (HPCU) Tray Location
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the solenoid valve connector (B) and inhibitor switch connector (A).

Fig 4: Locating Solenoid Valve Connector And Inhibitor Switch Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the shift cable (C) after removing the nut (A) and the bolts (B).
Tightening torque:

(A) 7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 lb-ft)

(B) 14.7 ~ 21.6 N.m (1.5 ~ 2.2 kgf.m, 10.9 ~ 15.9 lb-ft)

Fig 5: Locating Hybrid Power Control Unit (HPCU) Shift Cable
Courtesy of HYUNDAI MOTOR AMERICA
Remove the ground line after removing the Bolt (A).

Fig 6: Hybrid Power Control Unit (HPCU) Ground Line Location
Courtesy of HYUNDAI MOTOR AMERICA
Remove the heater protector mounting Bolt (A).

Fig 7: Removing Heater Protector Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the ATF warmer hose (A).

Fig 8: Locating ATF Warmer Hose
Courtesy of HYUNDAI MOTOR AMERICA
CAUTION:
- Carefully install the clamp to prevent damage to the hose.
- Install the clamp in a correct direction not to be interfered with other parts.
- After the installation, start the engine and then check if there are any leaks from the hose.
Disconnect the high voltage connector (A) of drive motor.

Fig 9: Locating Drive Motor High Voltage Connector
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
Disconnect method of the connector
1. Pull the lever (A) in the direction of the arrow in illustrations below.
  
  Fig 10: Pulling Drive Motor High Voltage Connector Lever
  Courtesy of HYUNDAI MOTOR AMERICA
2. Press the lever (B), and then pull the connector by rotating the lever (C).
  
  Fig 11: Pressing Drive Motor High Voltage Connector Lever
  Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the Electric Oil Pump (EOP) connector (A).

Fig 12: Locating Electric Oil Pump (EOP) Connector
Courtesy of HYUNDAI MOTOR AMERICA
Remove the Clutch Pressure Sensor (CPS) connector (A).

Fig 13: Clutch Pressure Sensor (CPS) Connector Location
Courtesy of HYUNDAI MOTOR AMERICA
Assemble the engine support fixture (Support SST No.:09200-2S000, Beam SST No.:09200-3N000) (Refer to SPECIAL SERVICE TOOLS "Engine support fixture assembly drawing")
Using the engine support fixture assembly, hold the engine and transaxle assembly safely.
NOTE:
* SST No. 09200-38001 model also can be used for removing the transaxle.

Fig 14: Holding Engine Using Engine Support Fixture Assembly
Courtesy of HYUNDAI MOTOR AMERICA
Remove the cover (A).

Fig 15: Automatic Transaxle Support Bracket Mounting Bolt Cover
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle support bracket mounting bolt (A).
Tightening torque:

88.2 ~ 107.8 N.m (9.0 ~ 11.0 Kgf.m, 65 ~ 79.5 lb-ft)

Fig 16: Locating Automatic Transaxle Support Bracket Mounting Bolt
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle mounting support bracket (A).
Tightening torque:

(A) 58.8 ~ 78.4 N.m (6.0 ~ 8.0 kgf.m, 43.3 ~ 57.8 lb-ft)

Fig 17: Removing Automatic Transaxle Mounting Support Bracket
Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle upper mounting bolt (A-2ea).
Tightening torque:

(A) 42.2 ~ 54.0 N.m (4.3 ~5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

Fig 18: Removing Automatic Transaxle Upper Mounting Bolt (A-2Ea)
Courtesy of HYUNDAI MOTOR AMERICA
Remove the sub frame. (Refer to Suspension System - "Sub Frame ")
Remove the drive shaft assembly. (Refer to Driveshaft and Axle - "Front Driveshaft ")
Press the lock, and then disconnect the sensor connector (A).

Fig 19: Locating Connector Of Sensor
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the wiring mounting clip (A).

Fig 20: Locating Wiring Mounting Clip
Courtesy of HYUNDAI MOTOR AMERICA
Disconnect the Electric Oil Pump (EOP) connector (A) and mounting clip (B).

Fig 21: Electric Oil Pump (EOP) Connector And Mounting Clip Location
Courtesy of HYUNDAI MOTOR AMERICA
NOTE:
Disconnect method of the connector
1. Pull the lever (A).
2. Press the hook (B), and then pulling the cable connector.
  
  Fig 22: Pressing Electric Oil Pump (EOP) Connector Hook
  Courtesy of HYUNDAI MOTOR AMERICA
3. Using the screw driver, raise the hook (C), and then pull the cable connector.
  
  Fig 23: Raising Electric Oil Pump (EOP) Connector Hook Using Screw Driver
  Courtesy of HYUNDAI MOTOR AMERICA
Remove the automatic transaxle with a jack after removing the mounting bolts (A, B).
Tightening torque:

42.2 ~ 48.1 N.m (4.3 ~ 4.9 kgf.m, 31.1 ~ 35.4 lb-ft)

Fig 24: Removing Automatic Transaxle With Jack
Courtesy of HYUNDAI MOTOR AMERICA