Kia Niro: Hybrid Motor Assembly / Hybrid Drive Motor Assembly Repair procedures

Kia Niro 2017 (DE HEV) Service Manual / Service Highlight / Hybrid Motor Assembly / Hybrid Drive Motor Assembly Repair procedures

Inspection

Inspect the resistance line to line using mΩ tester.

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

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)

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 %

Inspect the insulation resistance.s

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
	Motor	Pin U - GND Pin V - GND Pin W - GND	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↑	DC 500 V, 1 minute

Removal

1.	Remove the hybrid drive motor & dual clutch transmission assembly from the vehicle. (Refer to DCT System - "DCT")

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")

Remove the hybrid drive motor (A) loosening the bolts.

Tightening torque :

42.2 - 53.9 N·m (4.3 - 5.5 kgf·m, 31.1 - 39.8 lb·ft)

Installation

Install in the reverse order of removal.

Matters that require attention when installing the dual clutch transmission assembly

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.

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.)

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 initialization of the engine clutch inspection line learning and diagnostic information using the GDS.

(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)	Perform of the stabilization of the engine clutch hardware transfer torque using the GDS.

Hybrid Drive Motor Assembly Specification

Specification Item Specification Type PMSM (Interior Permanent Magnet Synchronous Motor) Max. output ...

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