Kia Niro: Hybrid Motor Assembly / Hybrid Drive Motor Assembly Repair procedures
| 1. |
Using mΩ tester, measure the line-to-line resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Phase-to-phase resistance
|
Pins U - V
|
36.0 mΩ ± 5 %
|
Deviation in phase-to-phase resistance at room temperature 68°F
(20°C): 5%
|
Pins V - W
|
Pins W - U
|
|
| 2. |
Inspect the temperature sensor resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Resistance (Temperature sensor)
|
Pins 4 - 8
|
10.92 - 13.44 kΩ
|
At room temperature 68°F (20°C)
|
|
| 3. |
Inspect the resolver sensor resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Resistance
(Resolver sensor)
|
Pins 1 - 5
|
11.7 Ω ± 10 %
|
At room temperature 68°F (20°C)
|
Pins 2 - 6
|
34.5 Ω ± 10 %
|
Pins 3 - 7
|
29.5 Ω ± 10 %
|
|
| 4. |
Inspect the insulation resistance.
Item
|
Inspection area
|
Specification
|
Remarks
|
Insulation
(housing, cover)
|
Motor
|
Pin U - GND
Pin V - GND
Pin W - GND
|
10 MΩ↑
|
DC 540 V, 1 minute
|
2.5 mA↓
|
AC 1600 V, 1 minute
|
Resolver sensor
|
Pin 1 - GND
Pin 2 - GND
Pin 3 - GND
|
10 MΩ↑
|
DC 500 V, 1 minute
|
Temperature sensor
|
Pin 4 - GND
|
10 MΩ↑
|
|
| 1. |
Remove the hybrid drive motor & dual clutch transmission assembly from
the vehicle.
(Refer to DCT System - "DCT")
|
| 2. |
Remove the engine clutch actuator (A).
|
Tightening torque :
21.6 - 26.5 N·m (2.2 - 2.7 kgf·m, 15.9 - 19.5 lb·ft)
|
|
| 3. |
Remove the concentric slave cylinder.
(Refer to Clutch System - "Concentric Slave Cylinder Assembly")
|
| 4. |
Remove the hybrid drive motor (A) by loosening the bolts.
|
Tightening torque :
42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)
|
|
| 1. |
Install in the reverse order of removal.
| 1) |
Check the pilot bearing (B) and motor side connector
(A) on the side of engine for any dents, damages and deformations
before installing the DCT.
|
| 2) |
Align the motor side connector spline (A) with the dual
clutch spline (B).
|
| 3) |
Insert the input shaft (A) into the pilot bearing (B)
and then assemble the DCT to the bushing on the motor side.
|
| 4) |
After mounting the DCT to the engine by pushing the DCT,
tighten the mounting bolts making sure that there is no
gap (less than 2 mm) between the clutch housing and the
engine block.
(If the bolt is tightened while there is a gap, then
the spline of motor side connector or clutch will be damaged
or broken.)
|
|
|
| 2. |
Perform the procedure below after installing.
| (1) |
Refill the hybrid motor cooling system with coolant and then
perform the air bleeding using the KDS/GDS.
(Refer to Hybrid Motor System - "Coolant")
|
| (2) |
Perform learning of the engine clutch inspection line and initialization
of diagnostic information using the GDS/KDS.
|
| (3) |
Refill the engine clutch reservoir with brake fluid and then
perform the air bleeding using the KDS/GDS.
|
| (4) |
Perform the engine clutch / motor resolver adaptation using the
KDS/GDS.
|
| (5) |
Stabilize the engine clutch hardware transfer torque using the
GDS/KDS.
|
|
Specification
Item
Specification
Type
PMSM
(Interior Permanent Magnet Synchronous Motor)
Max. output
...
Components
1. Hybrid starter generator (HSG)
2. HSG bracket
...
Hybrid Drive Motor Assembly Specification
Hybrid Starter Generator(HSG) Components and components location