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 before doing any work related with the high voltage system(Refer to "High Voltage Shut-off Procedure"). Failure to follow the safety instructions may result in serious electrical injuries.

Hybrid Power Control Unit (HPCU)

1.

Shut off the high voltage circuit.

(Refer to Hybrid Control System - “High Voltage Shutoff Procedure”)

2.

Remove the air cleaner assembly and air duct.

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

3.

Remove the ECM & TCM bracket assembly.

(Refer to Engine Control/Fuel System - "Engine Control Module")

4.

Drain the coolant of hybrid motor cooling system.

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

5.

Remove the HPCU protector (A) after loosening the mounting bolts.

6.

Disconnect the motor power cable connector (A) and HSG power cable conector (B).

7.

Disconnect the power cable (A) [↔ High voltage battery system assembly] and power cable (B) [↔ HSG & Electric A/C compressor].

  

Remove the inverter power cale in the follwing order.

8.

Disconnect the HCU & inverter (MCU) connector (A).

9.

Disconnect the coolant outlet hose & pipe (A) after loosening the mounting bolt.

10.

Disconnect the LDC power output cable (A) and LDC ground (-) cable (C) after loosening the mounting bolt and nut.

LDC power (12V) output cable mounting nut :

10.8 - 13.7 N·m (1.1 - 1.4 kgf·m, 7.9 - 10.1 lb·ft)

LDC ground cable mounting bolt :

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

11.

Remove the HPCU (B) after looening the mounting bolts.

HPCU mounting bolt :

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

12.

Remove the coolant hose & pipe (A) from the HPCU.

13.

Remove the reservoir (B) after loosening the mounting bolts.

Reservoir mounting bolt :

3.9 - 5.9 N·m (0.4 - 0.6 kgf·m, 2.9 - 4.3 lb·ft)

Hybrid Power Control Unit (HPCU) Tray

1.

Remove the hybrid power control unit.

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

2.

Remove the hybrid power control unit tray (A) after loosening the mounting bolts.

Hybrid Power Control Unit (HPCU) tray mounting bolt :

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 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 ofthe motor. Like the CMP sensor on the engine, it detects the position of t ...

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