Kia Niro: Hybrid Motor Assembly / Hybrid Starter Generator(HSG) Repair procedures

Kia Niro 2017 (DE HEV) Service Manual / Hybrid Motor System / Hybrid Motor Assembly / Hybrid Starter Generator(HSG) Repair procedures

Inspection
1.

Inspect the line to line resistance using mΩ tester.

Item
Pin
Specification
Remarks
Resistance
(Line - Line)
U - V
Average ± 5%
At room temperature 68°F (20°C)
V - W
W - U

2.

Inspect the temperature sensor resistance.

Item
Pin
Specification
Remarks
Resistance
(Temperature sensor)
4 - 9
121.6 - 133.14 kΩ
At room temperature 68°F(20°C)

3.

Inspect the resolver sensor resistance.

Item
Pin
Specification
Remarks
Resistance
(Resolver sensor)
1 - 4
11.7Ω ± 10%
At room temperature 68°F (20°C)
2 - 5
32Ω ± 10%
3 - 6
30Ω ± 10%

4.

Inspect the insulation resistance.

Item
Inspection area
Specification
Remarks
Insulation resistance
(Housing, Cover)
Motor
Pin U - GND
Pin V - GND
Pin W - GND
GND
DC 540 V, 1 min
5 mA↓
AC 1600V, 1 min
Resolver sensor
Pin 1 - GND
Pin 2 - GND
Pin 3 - GND
10 MΩ↑
DC 500 V, 1 min
Temperature sensor
Pin 4 - GND
10 MΩ↑

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 Hybrid Motor System - "High Voltage Shut-off Procedure")

2.

Drain the coolant from the hybrid cooling system.

(Refer to Hybrid Motor Cooling System - "Coolant")

3.

Remove the air cleaner assembly.

(Refer to Engine Mechanical System - "Air Cleaner")

4.

Remove the drive belt.

(Refer to Engine Mechanical System - "Drive Belt")

5.

Remove the drive belt tensioner.

(Refer to Engine Mechanical System - "Drive Belt Tensioner")

6.

Remove the idler.

(Refer to Engine Mechanical System - "Idler")

7.

Disconnect the HSG connector (A).

8.

Disconnect the cooler hose (A) from the HSG.

9.

Remove the intake manifold.

(Refer to Engine Mechanical System - "Intake Manifold")

10.

Loosen the HSG mounting nut (A) and bolt (B).

Tightening torque :

44.1 - 49.0 N·m (4.5 - 5.0 kgf·m, 32.5 - 36.2 lb·ft)

11.

Remove the HSG after removing the HSG bracket (A).

Tightening torque :

55.9 - 60.8 N·m (5.7 - 6.2 kgf·m, 41.2 - 44.8 lb·ft)

Installation
1.

Install in the reverse order of removal.

  

Be careful not to damage other hoses nearby when tightening the clamp.

Install the clamp in the specified direction to prevent interference with surrounding components.

2.

Perform the procedure below after installing.

(1)

Refill the hybrid cooling system with coolant and bleed air from the hybrid cooling system using GDS/KDS.

(Refer to Hybrid Motor Cooling System - "Coolant")

(2)

Perform the engine clutch / motor resolver adaptation using the KDS/GDS.

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