Kia Niro: Dual Clutch Transmission Control System / Gear Actuator 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 circuit according to the “High Voltage Shut-off Procedures” before doing any work related with the high voltage system to avoid serious electrical injuries.

1.

Shut off the high voltage circuit.

(Refer to Automatic Transaxle System - "High Voltage Shut-off Procedure")

2.

Drain the coolant of hybrid cooling system.

(Refer to Hybrid Motor System - "Coolant")

3.

Remove the hybrid power control unit (HPCU) assembly.

(Refer to Hybrid Control System - "Hybrid Power Control Unit")

4.

Disconnect the TCM connector (A) and ECM connector (B).

5.

Remove the TCM (A) and ECM (B).

Tightening torque :

9.8 - 11.8 N·m (1.0 - 1.2 kgf·m, 7.2 - 8.7 lb·ft)

6.

Remove the HPCU tray (C) after removing the nut (A) and wiring mounting clips (B).

Tightening torque :

(A) 10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 8.0 - 10.1 lb·ft)

(C) 21.6 - 23.5 N·m (2.2 - 2.4 kgf·m, 15.9 - 17.4 lb·ft)

7.

Disconnect the gear actuator motor connector (A) and gear actuator solenoid connector (B).

8.

Remove the gear actuator assembly after loosening bolts (A, B).

Tightening torque :

(A) 19.6 - 26.5 N·m (2.0 - 2.7kgf·m, 14.5 - 19.5 lb·ft)

(B) 9.8 - 11.8 N·m (1.0 - 1.2kgf·m, 7.2 - 8.7 lb·ft)

Installation
1.

Install in the reverse order of removal.

  

Check the following before installing the gear actuator assembly.

1)

Check that the gear actuator is placed in the "neutral" state.

2)

Check the assembled state of the O-rings (A).

3)

Apply gear oil to the surface of O-rings.

4)

Check the assembled state of the dowel pins (A).

Perform the clutch touch point learning procedure using the KDS/GDS after replacing the gear actuator assembly.

Gear Actuator Assembly Schematic diagrams
Schematic Diagrams ...

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