Kia Niro: High Voltage Battery Cooling System / Cooling Fan 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.

Shut off the High Voltage circuit.

(Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.

Remove the high voltage battery front cover.

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

3.

Disconnect the cooling fan connector (A).

4.

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

Cooling fan mounting nut / bolt :

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 cooling fan in the reverse order of removal.

Inspection
1.

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

2.

Connect the oscilloscope probe to the BMS extension connectors.

Cooling Fan Speed Waveform:

BMS Extension Connector B01-S(20)

Cooling Fan Feedback Waveform:

BMS Extension Connector B01-S(4)

3.

Switch "ON" the ignition.

4.

Using KDS/GDS, perform "Actuation Test" and inspect the "current and waveform in each fan operation mode".

Duty

Duty (%)
Fan Speed (rpm)
10
-
20
1,000
30
1,300
40
1,600
50
1,900
60
2,200
70
2,500
80
2,800
90
3,100
95
3,850

[Cooling Fan at 1st]

[Cooling Fan at 2nd]

[Cooling Fan at 3rd]

[Cooling Fan at 4th]

[Cooling Fan at 5th]

[Cooling Fan at 6th]

[Cooling Fan at 7th]

[Cooling Fan at 8th]

[Cooling Fan at 9th]

Cooling Fan Description and operation
Description Consisting of the main connector, the cooling fan relay and the BLDC motor, the cooling fan is controlled by the BMS ECU PWM signal which varies with the high voltage batt ...

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Other information:

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