Kia Niro: High Voltage Battery System / Battery Pack Assembly Repair procedures

Removal
  

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.

1.

Remove the high voltage battery system assembly.

(Refer to High Voltage Battery System - "Removal")

2.

Remove the BMS ECU after loosening the mounting nuts.

BMS ECU mounting nut :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

3.

Remove the safety plug cable (A) after loosening the mounting bolts and nut.

4.

Remove the cooling fan (A) after loosening the mounting bolt and nuts.

5.

Remove the BMS ECU extension wiring harness (A).

6.

Remove the power relay assembly (A) after loosening the mounting nuts.

Power relay assembly mounting nut :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

Installation
  

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.

1.

Install the high voltage battery pack assembly in the reverse order of removal.

Inspection
[Battery Pack Assembly Troubleshooting Chart]

  

For SOC check, refer to “SOC Inspection”

For voltage check, refer to “Battery Voltage Inspection”

For battery voltage sensing circuit, refer to "Voltage Sensing Circuit Inspection"

For insulation resistance check, refer to "Insulation Resistance Inspection".

[SOC Level and Follow-up]
SOC
Symptom
Warning Lamp
Follow-up
MIL
Service
Fuel

Normal

-
-
-
 
10 ~ 15%

Motor torque limit

(Acceleration delay)

-
-
ON

Refuel and check the SOC again

ON
-
-

Repair the MIL or Service Lamp related system

Charge the battery by starting the engine

Refuel if necessary

ON
ON
-
-
ON
-
On
ON
ON
5 ~ 10%

EV mode inhibited

FATC inhibited

LDC inhibited

-
-
ON

Refuel and check the SOC again

ON
-
-

Repair the MIL or Service Lamp related system

Charge the battery by starting the engine

Refuel if necessary

ON
ON
-
-
ON
-
ON
ON
ON
0 ~5%

Impossible to start

ON
-
-

Repair the MIL or Service Lamp related system

Start the engine with KDS/GDS to charge the battery

Refuel if necessary

ON
ON
-
-
ON
-
ON
ON
ON
Below 0%
ON
-
-

Repair the MIL or Service Lamp related system

If necessary, Replace Battery Pack

Refuel if necessary


[SOC Inspection]
1.

Connect the KDS/GDS to the Data Link Connector (DLC).

2.

Switch "ON" the ignition.

3.

Check the SOC in GDS service data.

SOC: Above 5 %

[Battery Voltage Inspection]
1.

Connect the KDS/GDS to the Data Link Connector (DLC).

2.

Switch "ON" the ignition.

3.

Check the cell and pack voltage in GDS service data.

Cell Voltage: Above 2.84 V

Pack Voltage: Above 181 V

[Voltage Sensing Circuit Inspection]
1.

Shut off the high voltage circuit (Refer to "High Voltage Shutoff Precedure").

2.

Remove the battery temperature sensor (Refer to "Battery Temperature Sensor").

3.

Check the continuity of the wiring between the harness connectors of the module and BMS ECU.

Specification : below 1Ω

4.

Connect the harness connectors to the BMS ECU.

5.

For checking the short circuit to ground, measure resistance between the module harness connectors and chassis ground.

Specification : 1MΩ or higher

[Insulation Resistance Inspection]
1.

Connect the KDS/GDS to the Data Link Connector (DLC).

2.

Switch "ON" the ignition.

3.

Check the insulation resistance in KDS/GDS service data.

Insulation Resistance: Approximately 1.0 MΩ

Battery Pack Assembly Specifications
Specification Battery Pack Assembly [General Specification] Item Specification Remarks Number of Cells 16 Cells × 4 ...

Power Relay Assembly (PRA) Specifications
Specification Power Relay Assembly (PRA) Item Specification Rated Voltage (V) 240 Rated Current (A) ...

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