Kia Niro: Hybrid Motor Control System / Motor Control Unit (MCU) 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 Hybrid Motor System - "High Voltage Shut-off Procedure")

2.

Drain the coolant of 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 HPCU cover (A).

5.

Remove the reservoir.

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

6.

Separate the hose (A) and loosen the bolt (B).

Tightening torque :

7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

7.

Remove the LDC power cable (A) and ground cable (B).

Tightening torque :

(A) 7.8 - 11.8 N·m (0.8 - 1.2 kgf·m, 5.8 - 8.7 lb·ft)

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

8.

Disconnect the drive motor high voltage cable connector (A) and HSG high voltage cable connector (B) and then remove the wiring mounting clip (C).

9.

Disconnect the high voltage battery cable connector (A) and the inverter high voltage cable connector (B).

10.

Disconnect the HCU & MCU connector (A).

11.

Remove the HCPU (A).

Tightening torque :

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

Installation
1.

Install in the reverse order of removal.

2.

Perform the procedure below after installing.

(1)

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

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

(2)

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

Motor Control Unit (MCU) Components and components location
Components Location 1. HPCU assembly ...

Resolver Sensor Description and operation
Description The accurate position of the rotor must be known at all times to ensure maximum output control of the motor. ...

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