Kia Niro: High Voltage Battery System / 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.

1.

Shut off the high voltage circuit.

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

2.

Remove the rear seat cushion.

(Refer to Body - "Rear Seat Assembly")

3.

Remove the rear door scuff trim.

(Refer to Body - "Door Scuff Trim")

4.

Remove the cooling duct.

(Refer to High Voltage Battery Cooling System - "Cooling Duct")

5.

Remove the upper frame (A) after loosening the mounting bolts and nuts.

High voltage battery system assembly upper frame mounting bolt :

19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

High voltage battery system assembly upper frame mounting nut (M8) :

19.6 - 29.4 N·m (2.0 - 3.0 kgf·m, 14.5 - 21.7 lb·ft)

High voltage battery system assembly upper frame mounting nut (M6) :

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

6.

Remove the high voltage battery rear cover (A) after loosening the mounting bolts and nuts.

High voltage battery rear cover mounting bolt / nut :

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

7.

Remove the high voltage battery front cover (A) after loosening the mounting bolts and nuts.

High voltage battery front cover mounting bolt / nut :

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

8.

Disconnect the BMS ECU extension wiring connector (A), inverter power connector [-] (B) and inverter power connector [+] (C)

9.

Remove the 12V junction box (D) after loosening the mounting nuts.

10.

Unfasten the high voltage battery system assembly (A) in the direction of arrow.

11.

Disconnect the auxiliary 12V battery wiring harness (A) after releasing the fixing hook.

12.

Remove the high voltage battery system assembly (A) from the vehicle.

Installation
  

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.

1.

Install the high voltage battery system in the reverse order of removal.

Components and components location
Components Location 1. High Voltage Battery System Assembly 2. High Voltage Battery Pack Assembly 3. Power Relay Assembly (PRA) 4. High Voltage Front ...

Battery Pack Assembly Specifications
Specification Battery Pack Assembly [General Specification] Item Specification Remarks Number of Cells 16 Cells × 4 ...

Other information:

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